Filling coolant

• 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 301, 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)  .

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• The filling process is completed more quickly if the canister is positioned at roughly the same height as the coolant reservoir  .

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• A hissing sound after connecting the compressed air supply is usual  .

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  .

1. Set up and connect vacuum filling device.
   1. 1.1. Fill coolant reservoir -5-  with at least 12 liters of pre-mixed coolant in the correct mixture ratio.
   2. 1.2. Screw the cap adapter K65 -6-  for the coolant reservoir onto the reservoir.
   3. 1.3. Connect the flexible extension (FZ 100) to the cap.
   4. 1.4. Connect the vacuum gauge KVB01 -7-  of the bleeder tool to the flexible extension and make sure that both shut-off valves -V1-  and -V2-  are closed.

      V1 and V2 are at 90° to the flow direction 

   5. 1.5. Connect the Venturi nozzle to the vacuum gauge.
   6. 1.6. Push the filler hose of the vacuum gauge onto the canister connection.
   7. 1.7. Route the return line -1-  from the Venturi nozzle to a second container -2-  .
   8. 1.8. Connect the compressed air supply -4-  to the filler hose -3-  .
   9. 1.9. Build up overpressure of 6 to 10 bar.

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2. Open → see figure below  both shut-off valves on the vacuum gauge until the transparent filler hose is completely filled with coolant.

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3. Close the left shut-off valve (V1) on the vacuum gauge and allow a vacuum to build up in the cooling system.

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4. Allow a sufficient vacuum to build in the cooling system (pointer is in the green area) → see figure below  .

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5. Close the right shut-off valve (V2) and then disconnect the compressed air supply.

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6. Re-open the left shut-off valve (V1) on the vacuum gauge. The cooling system is then filled. → see figure below 

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7. When there is no trace of vacuum present and no more coolant is being drawn from the canister, open the right shut-off valve (V2). → Opening right shut-off valve 

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8. Then remove the complete filling tool (including the adapter K65).
9. Loosen and pull back the coolant hose to the heat exchanger for the heater until coolant emerges from the ventilation bore -1-  in the coolant hose.
   1. 9.1. Collect emerging coolant with a cloth.

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10. Push coolant hose onto the adapter and secure with the spring band clamp.
11. For vehicles with an auxiliary heater, switch this on and allow it to run for approx. 30 seconds.
12. Close the cap on the reservoir.
13. Start the engine and leave it running at idle speed. Move the selector lever to position "P" and allow the engine to warm up.
14. Switch on passenger compartment heating.

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15. Press the "Sport button". Leave "Sport" mode activated during the bleeding process.
16. Check the following while the vehicle is warming up:
    1. 16.1. Coolant temperature -2-  and engine oil temperature -1-  in the instrument cluster. Figure shows normal, acceptable values.

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       Duration	Engine speed	Conditions
       3 minutes	2, 000 RPM	With air conditioning "Off" Heater "HI", blower setting at one bar
       until both coolant hoses on the radiator are warm	Idle speed	With air conditioning "Off" Heater "HI"
       2 minutes	2, 000 RPM	With air conditioning "Off" Heater "HI"

17. The cooling system has been filled and bled correctly if →
    • All coolant hoses are uniformly warm.
    • The temperature display in the instrument cluster is in the normal range.
    • Passenger compartment heating is warm.
    • The electric fan for engine cooling comes on.
18. Correct level:
    • When the engine is cold the coolant level must be up to the -MAX- marking.
    • When the engine is at operating temperature the engine coolant level may be above the -MAX- marking.