Filling Coolant (High-Temperature Cooling System)

→ Do not start the engine after relieving the system pressure.

→ Fill the cooling system correctly and bleed it before starting the engine.

1. If you have not already done so, screw cap adapter K65 for the coolant reservoir onto the reservoir.
2. Connect the flexible extension (FZ 100) to the cap.
3. Connect the vacuum pressure gauge of the bleeder tool to the flexible extension. When doing so, ensure that both shut-off valves are closed (positioned at 90° with respect to flow direction).
4. Connect the Venturi nozzle to the vacuum gauge. -arrow- 
   Fig 1: Connecting Venturi Nozzle To Vacuum Gauge

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   Information 

   • The amount of coolant available must be approx. 2 liters more than the amount to be filled in  .
   • Because different quantities of coolant can drain away during different types of repairs, the filling capacity can vary greatly. Recommendation: To be on the safe side, fill the canister to 30 l, then bleed the cooling system. The difference after bleeding is the coolant quantity that is sucked in. Check the volume scale on the canister  .
   • An antifreeze content of -35 °C corresponds to a mixture of 50: 50 (antifreeze: water)  .
5. Place a canister with a sufficient amount of coolant and with an antifreeze content of -35 °C beside the vehicle close to the reservoir.

   Information 

   • The filling process is completed more quickly if the canister is positioned at roughly the same height as the coolant reservoir  .
6. Push the filler hose -5-  of the vacuum gauge onto the canister connection. Route the return line -6-  from the Venturi nozzle to a second container (bucket).
   Fig 2: Identifying Vacuum Filling Device Components

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   Information 

   • A hissing sound after connecting the compressed air supply is usual  .
7. Connect the compressed air supply.
   Fig 3: Connecting Compressed Air Supply

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8. Open both shut-off valves on the vacuum gauge → see Fig 4 until the transparent filler hose is completely filled with coolant.
   Fig 4: Identifying Shut-Off Valves

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9. Close the left shut-off valve (V1) -arrow-  on the vacuum gauge and allow a vacuum to build up in the cooling system.
   Fig 5: Locating Left Shut-Off Valve

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   Information 

   • If no vacuum is generated (the pointer does not move to the green area), there is a leak in the cooling system  .
   • If a vacuum is still not established, there is a blockage in the tool. Clean the device, use clean compressed air  .
   • Deformation of the rubber hoses of the cooling system is normal  .
   • Pressure of between 6 and 10 bar must be present. The higher the pressure, the better the vacuum in the vehicle cooling system  .
   • When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has been built up  .
   • After both shutoff valves on the vacuum pressure gauge have been closed and the compressed air supply has been disconnected, the vacuum must not drop. If the vacuum drops within approx. 30 seconds, there is a leak in the coolant circuit  .
10. When there is a sufficient vacuum in the cooling system (pointer is in the green area), close the right shut-off valve (V2) and then disconnect the compressed air supply.
    Fig 6: Identifying Right Shut-Off Valve

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11. Open the left shut-off valve (V1) on the vacuum gauge again. The cooling system is then filled.
12. When there is no trace of vacuum present or the coolant is no longer drawn from the canister, open the right shut-off valve (V2).

    → see Fig 7

    Fig 7: Identifying Shut-Off Valves

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13. Then remove the complete filling tool (including the adapter K65).
14. Check the coolant level in the reservoir. Top up or drain coolant as required until the coolant is at the "MAX"  marking.
    Fig 8: Identifying Coolant Reservoir Marking

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