Filling coolant (includes bleeding)

Information 

The process of filling and bleeding the cooling system is performed using the special tool filling device 9696  .

Information 

• In all Cayman vehicles and in Boxster vehicles from MY 2007, the coolant expansion tank is located in the engine compartment. 
• Testing and inspection work can be performed via the opening in the service tray (right). 
• Filling and bleeding work are performed on the coolant expansion tank. 

1. Fit the vehicle protective covers.
2. Protect the luggage compartment against soiling with a cover.
3. Screw cap adapter for coolant expansion tank (K22) onto the tank and attach flexible extension (Fz100) to the cap.
   Fig 1: Checking Filling Coolant Using Tool (View Of Boxster)

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   Fig 2: Checking Filling Coolant Using Tool (Cayman And Boxster From 2007)

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4. Connect vacuum pressure gauge of bleeder tool to the flexible extension. When doing so, ensure that both shutoff valves are closed (positioned at 90° to flow direction).
5. Connect the Venturi nozzle to the vacuum pressure gauge.
   Fig 3: Connecting Venturi Nozzle On Vacuum Pressure Gauge

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   Information 

   • The quantity of coolant available should exceed the amount required to fill the system by about two litres in order to prevent air being sucked in. 
   • An antifreeze content of -35 °C corresponds to a mixture of 50:50 (coolant:water). 
6. Place a canister with a sufficient amount of coolant and with an antifreeze content for -35 °C behind the vehicle near to the expansion tank

   Information 

   • The bleeding process is completed more quickly if the canister is positioned at the same height as the coolant reservoir  .
7. Push the filler hose of the vacuum pressure gauge -5-  onto the canister connection. Draw off the return line -6-  of the Venturi nozzle into a second container.
   Fig 4: Pushing Filler Hose Of Vacuum Pressure Gauge On Canister Connection

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   Information 

   • A hissing sound after connecting the compressed air supply is normal  .
8. Connect compressed air supply to Venturi nozzle
   Fig 5: Compressing Air Supply On Venturi Nozzle

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9. Open both shutoff valves on the vacuum pressure gauge until the transparent filler hose has completely filled with coolant.
   Fig 6: Identifying Shutoff Valves Open

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10. Close left shutoff valve on the vacuum pressure gauge -arrow-  and allow a vacuum to build up in the coolant circuit.
    Fig 7: Locating Shutoff Valve On Vacuum Pressure Gauge

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    Information 

    • If no vacuum is built up, there is a leak in the cooling system or the connection pressure is too low. 
    • Deformation of the rubber hoses in the cooling system is normal. 
    • When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has been built up. 
    • If both shut-off valves are closed and the compressed air supply is disconnected, the vacuum must not drop. 
    • If the vacuum drops within approx. 30 seconds, there is a leak in the cooling system  .
11. When there is enough vacuum in the cooling system, close right shutoff valve and subsequently unplug the compressed air supply.
    Fig 8: Identifying Vacuum Established (Pointer In Green Region)

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12. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow-  ). The cooling system is then filled.
    Fig 9: Locating Right-Hand Valve Closed

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13. When the cooling system no longer contains a vacuum (vacuum pressure gauge shows zero), i.e. no more coolant is being sucked out of the canister, open right-hand shutoff valve.
14. Now remove the complete filling device filling device 9696  (including cap K 22).
15. If necessary, fill the coolant expansion tank with coolant up to the maximum marking and screw on the cap of the expansion tank (do not tilt).
    Fig 10: Tightening Cap (View Of Boxster)

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