Draining, Filling & Bleeding Cooling System

WARNING: Cooling system is pressurized, when engine is at operating temperature. Use caution and appropriate protective gear when servicing cooling system. Slowly and carefully release system pressure, before performing any repairs.

Turn engine off, and allow to cool. Open rear luggage compartment. Using a suitable cover, protect trunk floor panel against spillage. Open expansion tank cap.
Raise and support vehicle. Remove underbody cover, below engine. See Fig 1 .

Fig 1: Removing Underbody Cover
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Place appropriate drain pan underneath vehicle. Remove engine drain plug. See Fig 2 . Drain coolant from engine.

Fig 2: Locating Engine Drain Plug
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Remove hose clamps from radiator supply and return lines. See Fig 3 . Carefully pull radiator supply, and return lines from engine, and drain coolant. Thoroughly clean hoses inside and out. Connect hoses, and tighten hose clamps. Ensure hoses are securely seated.

Fig 3: Locating Radiator Supply & Return Lines
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Remove hose clamps to heating lines. See Fig 4 . Pull of heating line hoses, and drain coolant. Thoroughly clean hoses inside and out. Connect hoses, and tighten hose clamps. Ensure hoses are securely seated. Using a NEW O-ring, install engine drain plug. Tighten drain plug to 88-132 INCH lbs. (10-15 N.m).

Fig 4: Locating Heating Lines
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NOTE: Ensure both shut off valves are in closed position (positioned 90° to flow direction) when attaching to flexible extension (Fz 100).

Fig 5: Attaching Adapter (K22)

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Screw lid adapter (K22) onto expansion tank. See Fig 5 . Connect flexible extension (Fz 100) onto lid adapter. Connect vacuum pressure gauge to flexible extension (Fz 100).

NOTE: Prepared coolant mixture must be approximately 2.1 qts. (2L) more than amount necessary to fill cooling system.

Fig 6: Connecting Pressure Gauge

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Connect Venturi nozzle (KVB 01) to vacuum pressure gauge. See Fig 6 . Place a canister with sufficient amount of coolant mixture, at rear of vehicle near expansion tank. See COOLING SYSTEM SPECIFICATIONS .

NOTE: Bleeding process is completed more quickly, if canister is positioned near same height as expansion tank.

Fig 7: Connecting Bleeder Hoses

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Place filler hose (5) of vacuum pressure gauge into canister. See Fig 7 . Guide return line (6) into a second container.

NOTE: Air pressure should be regulated to 87-145 psi (6-10 bar). A hissing sound will be audible, when compressed air supply is connected to lines.

Fig 8: Connecting Compressed Air To Venturi Nozzle

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Connect compressed air supply to Venturi nozzle. See Fig 8 .
Open both shut off valves on vacuum pressure gauge, until transparent filler hose begins to fill with coolant. Close left shut off valve (V1), on vacuum pressure gauge. See Fig 9 . This will create a vacuum build up in coolant circuit.

Fig 9: Identifying Vacuum Pressure Gauge Valves
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CAUTION: If vacuum does not build up, or if vacuum drops within approximately 30 seconds, there is a leak in cooling system.

NOTE: Deformation of rubber hoses is normal, during process.

NOTE: After both shut off valves have been closed, and compressed air supply has been unplugged, vacuum must not drop.

If indicator of pressure gauge is in Green area, enough vacuum has been built up. When enough vacuum has been obtained in cooling system, close right shut off valve (V2). Disconnect compressed air supply.

NOTE: This procedure takes approximately 5 minutes.

Reopen left shut off valve (V1), on compressed air pressure gauge. See Fig 9 . Cooling system will now be filled. When there is not trace of vacuum present, or coolant is no longer suctioned from canister, open right shut off valve (V2). Remove complete filling tool, including lid (K22).
Check coolant level, and top off as necessary, to MAX mark on expansion tank. When engine is cold, and vehicle is level, coolant level should be between MIN and MAX marks, on expansion tank.
Install underbody cover. Test drive vehicle. Turn engine off, and allow to cool. Check coolant level, and top off as necessary to MAX mark on expansion tank.