Filling Coolant And Bleeding The System

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Information 

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

Information 

• The quantity of coolant available should exceed the amount required to fill the system by about two liters in order to prevent air being sucked in. 
• An antifreeze content of -35 °C corresponds to a mixture of 50:50 (coolant: water). 

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. 

1. Fit new seals on drain plugs and tighten drain plugs.

   Tightening torque: 10 Nm (7.5 ft. lb.) 

2. Fit the spring clamps on the Henn couplings.

   Information 

   • Check O-rings on the plug-in couplings and replace them if necessary. 
   • Clean plug connection and coolant hoses before assembly. 
   • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
   • Remove stoppers before fitting the coolant lines and hoses. 

   Information 

   • The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 
3. Fit new O-rings on coolant hoses (if required). Pull to check that the connections are secure.
4. Screw cap adapter for coolant reservoir (K22) onto the tank and attach flexible extension (Fz 100) to the cap.
   Fig 1: Identifying Coolant Reservoir Adapter

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension.
   1. 5.1. When doing so, ensure that both shut-off valves are closed (positioned at 90° with respect to flow direction).
6. Connect the Venturi nozzle to the vacuum pressure gauge.
   Fig 2: Connecting Venturi Nozzle On Vacuum Pressure Gauge

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • The bleeding process is completed more quickly if the canister is positioned at the same height as the coolant reservoir. 
7. Place a canister with a sufficient amount of coolant and with an antifreeze content for -35 °C behind the vehicle close to the reservoir.
8. Push the filler hose of the vacuum pressure gauge -5-  onto the canister connection. Draw off the return line -6-  from the Venturi nozzle into a second empty container.
   Fig 3: Identifying Special Canister Filling Tool

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • A hissing sound after connecting the compressed air supply is normal. 
9. Connect the compressed air supply to the Venturi nozzle.
   Fig 4: Connecting Compressed Air Supply On Venturi Nozzle

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
10. Open both shut-off valves on the vacuum pressure gauge until the transparent filler hose has completely filled with coolant.
    Fig 5: Identifying Shutoff Valves Open

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
11. Close left shut-off valve on the vacuum pressure gauge and allow a vacuum to build up in the coolant circuit.
    Fig 6: Identifying Left-Hand Shutoff Valve Closed

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
12. When there is enough vacuum in the cooling system → Vacuum established (pointer in green region)  , close right shutoff valve and then unplug the compressed air supply.
    Fig 7: Identifying Vacuum Gauge

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
13. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow-  ). The cooling system is then filled.
    Fig 8: Identifying Left-Hand Shutoff Valve Open

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
14. 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 the right-hand shut-off valve.
15. Now remove the complete filling device filling device 9696  (including cap K 22).
16. If necessary, fill the coolant reservoir with coolant up to the maximum marking and screw on the cap of the reservoir (do not tilt).