Filling the coolant circuit with the vacuum filling equipment

Vacuum filling equipment

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Vacuum filling equipment - connected to the high-temperature coolant expansion tank

1 Vacuum filling equipment with pressure gauge and shutoff valves

2 Filling hose

3 Fluid tank with coolant

4 Venturi nozzle

5 Compressed air connection (7 bar)

6 Exhaust hose (route exhaust hose into a collecting vessel)

Precondition

The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filling equipment must have a sufficient quantity of premixed coolant, 1 l to 2 l more than the specified capacity for the vehicle. The fluid tank of the vacuum filling equipment must be positioned at the same height as the coolant expansion tank. The compressed air connection must have a pressure of 7 bar. Ignition is switched off.

The vacuum filling equipment must be functional and free of dirt.

NOTE: TECHNICAL INFORMATION
Follow notes for repair work on the cooling system.
For additional information see: NOTES FOR WORK ON THE COOLING SYSTEM (COUNTRYMAN 2017-2023, EXCEPT PHEV) .

NOTE: TECHNICAL INFORMATION
Immobilization period-iong fill of coolant!
Do not reuse used coolant.
When replacing and removing components which rely on the corrosion protection effect of the coolant, it is essential to change the coolant. The cooling system must therefore be emptied and refilled.
In the case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant.

NOTE: TECHNICAL INFORMATION
Filling without the vacuum filling equipment (watering can filling) is not permitted .
If this is not observed, there is a risk of component damage or engine damage.
The filling specification must be observed.
It is essential to visually check the vacuum filling equipment before use to check that it is functioning correctly and clean.
It is not permissible to operate the vehicle if the filling procedure has not been fully completed. Otherwise there may be functional limitations (degradation) or overheating.
A bleeding procedure is required after a part has been exchanged in the cooling system and/or after refilling the cooling system.

NOTE: TECHNICAL INFORMATION
Make sure that the ignition (terminal 15) is switched off prior to creating the vacuum with the vacuum filling equipment.

NOTE: TECHNICAL INFORMATION
When using vacuum filling equipment to fill the coolant circuit, you must use special tool 5 A31 EF2 (strainer) to protect the inside of the coolant circuit from contaminants.

Connect special tool (2) 5 A31 EF2 to the vacuum filling equipment (1).
Connect the special tool (2) with the appropriate adapter (3) from the set of special tools 0 494 417 (17 0 100) .

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Select a suitable adapter (Y) from the set of special tools 0 494 417 (17 0 100):

Type	Engine	Adapter (Y) from 17 0 100
F56/F55/F56/F57/F60	B36, B38, B46, B48, B37, B47	17 0 109

Fill the fluid tank of the vacuum filling equipment with 1 l to 2 l more than the filling capacity of coolant specified for the vehicle.

TECHNICAL DATA SPECIFICATION

Coolant filling quantity in the cooling system
	B38A15M1, B38A15U1, B36A15M1 with manual transmission without auxiliary radiator	6.75 l
	B38A15M1, B38A15U1, B36A15M1 with manual transmission with auxiliary radiator	7.45 l
	B38A15M1, B38A15U1, B36A15M1 with automatic transmission without auxiliary radiator	7.0 l
	B38A15M1, B38A15U1, B36A15M1 with automatic transmission with auxiliary radiator	7.7 l
	B38A15M1, B38A15U1, B36A15M1 with DCT without auxiliary radiator	7.1 l
	B38A15M1, B38A15U1, B36A15M1 with DCT with auxiliary radiator	7.8 l

Connect the selected adapter (Y) to the coolant expansion tank.
Connect the vacuum filling equipment on the connection (X) of the adapter.

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Check whether the shutoff valves (A) and (B) of the vacuum filling equipment (1) are closed.
Connect and lock connection (X) to the coolant expansion tank.

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Connect Venturi nozzle (1) to the vacuum filling equipment (2).
(X) is the connection on the coolant expansion tank.

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Connect compressed air (1).
(X) is the connection to the coolant expansion tank.

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Open shutoff valve (B).
The venturi nozzle generates a flow noise.

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Open shutoff valve (A) until the filling hose (1) is full without bubbles.
Close the shutoff valve (A) again.
» The filling hose (1) has now been bled.

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Check the coolant hoses for porosity and, if necessary, replace them.

NOTE: TECHNICAL INFORMATION
The coolant hoses contract during vacuum build-up.

After a vacuum of -0.8 to -0.95 bar has been reached in the coolant circuit (duration approximately 2 minutes), close the shutoff valve (B).

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Check whether shutoff valves (A) and (B) are closed.
Disconnect the Venturi nozzle (1).

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Check

The vacuum in the coolant circuit must be maintained for at least 2 minutes.

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Result

» Vacuum drops.

Measure

Search for leaks, repair them, and start the filling procedure from the beginning.

Check

The vacuum in the coolant circuit must be maintained for at least 2 minutes.

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Result

» Vacuum remains constant.

Measure

Continue with filling.

Keep shutoff valve (B) closed during the filling process.
To fill the cooling system, open shutoff valve (A) to the fluid tank of the vacuum filling equipment.

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Stop the filling procedure when the needle in the pressure tester is on 0 bar or it no longer drops.
If necessary, reduce remaining vacuum. To do so, open the shutoff valve (B).

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Remove the vacuum filling equipment with the adapter from the coolant expansion tank.
Adjust the coolant level to 400 ml above the maximum mark.
After filling the engine cooling system with the vacuum filling equipment, also carry out the cooling system bleeding procedure.

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