Filling Coolant

Information 

• Vacuum-fill cooling systems with thermal management (controlled thermostats or coolant valves for controlling engine temperature). 
• The thermostat must not be activated or electric current must not be applied to the thermostat since this can cause irreparable damage to the thermocouple. 
• Filling with a watering can only does not always guarantee a complete fill. 
• Clamps on cooling system components should be examined carefully following refilling (check the coolant level while cold and top up several times as required). 
• Clamps on cooling system components must also be vacuum-filled if significant amounts of coolant are drained. Drain at least two litres of coolant for vacuum-filling because otherwise a vacuum cannot be built up. 

Information 

• Because different quantities of coolant can drain away during different types of repairs, the filling capacity can vary greatly. 
• To be on the safe side, always fill the canister with more coolant than was drained. 
• The amount of coolant that was actually added can then be read off the volume scale on the canister. 
• An antifreeze content of -35°C corresponds to a mixture ratio of 50: 50 (antifreeze: water). 

Information 

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

Information 

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

Information 

• If a vacuum does not build up, there is a leak in the cooling system. 
• This can also be caused by a blockage in the Venturi nozzle. Clean the tool. 
• Deformation of the rubber hoses of the cooling system is normal. 
• Set a pressure of at least 8 bar. 
• When the pressure gauge pointer is in the green area of the display scale, a sufficient vacuum has been built up. 
• After both shut-off valves on the vacuum gauge are closed, disconnect the compressed air supply. 
• The vacuum must not drop; if it does, there is a leak in the cooling system. 

1. Make sure that the service clip on the coolant reservoir is open (vertical position).

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   Service clip on bleeder valve

2. Connect compressed air supply to compressed air connection -3-  .
   1. 2.1 Screw cap adapter KS 65 -6-  onto the coolant reservoir.
   2. 2.2 Connect the flexible extension (FZ 100) to the cap.
   3. 2.3 Close shut-off valves -V1-  and -V2-  (90° with respect to flow direction).
   4. 2.4 Connect the vacuum gauge -7-  of the bleeder tool to the flexible extension (FZ 100).
   5. 2.5 Connect Venturi nozzle to the vacuum gauge -7-  .
   6. 2.6 Place the filling canister -5-  beside the vehicle, close to the reservoir.
   7. 2.7 Push the filler hose of the vacuum gauge -7-  onto the canister connection. Route the return line -1-  from the Venturi nozzle into a second overflow container -2-  .

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   Connecting compressed air supply

3. Open the shut-off valves on the vacuum gauge > Opening shut-off valves  until the filler hose is completely filled with coolant.

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   Opening shut-off valves

4. Close the left shut-off valve (V1) > Closing shut-off valve on filler hose  on the vacuum gauge and allow a vacuum to build up in the cooling system.

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   Closing shut-off valve on filler hose

5. 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.
   1. 5.1 To check the system for leaks, a constant vacuum must be present for 30 seconds! 

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   Right shut-off valve

6. Connect > VAS 6096/2 - electric vacuum pump -3-  to Venturi nozzle.

   Do not use electric vacuum pump for more than 5 minutes! 

   1. 6.1 Switch on > VAS 6096/2 - electric vacuum pump -3-  and open the shut-off valve at the Venturi nozzle for the pump connection.
   2. 6.2 Check the amount of coolant in the overflow tank -4- while using the electric vacuum pump! 
   3. 6.3 Close the shut-off valve at the Venturi nozzle after 5 minutes and switch off the > VAS 6096/2 - electric vacuum pump  .
   4. 6.4 Disconnect connecting hose -2-  from the > VAS 6096/2 - electric vacuum pump  to the Venturi nozzle.

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   Electric vacuum pump VAS 6096/2 with Venturi nozzle

   1	Filling device 9696
   2	Connecting hose to overflow tank
   3	Electric vacuum pump VAS 6096/2
   4	Overflow tank
   5	Hose from overflow tank to electric vacuum pump IMPORTANT: (There must be no coolant in the hose!)
   Arrows	Shut-off valves

7. The pointer -1-  on the pressure gauge -2-  is approx. 5 mm below the end mark of the green area -Arrow-  .

   Result: Vacuum is OK! 

   1. 7.1 To check the system for leaks, a constant vacuum must be present for 30 seconds! 

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   Pressure gauge display after using the electric vacuum pump

8. New pressure gauge display for > 9696 - filling device  .
   1. 8.1 Green area -1-  = vacuum range without electric vacuum pump.
   2. 8.2 Blue area -2-  = vacuum range with electric vacuum pump.

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   Pressure gauge display for VAS 6069/2

9. Re-open the left shut-off valve (V1) on the vacuum gauge. The cooling system is then filled.
10. When there is no vacuum whatsoever present or when coolant is no longer drawn from the canister, open the right shut-off valve (V2) > Shut-off valve 

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    Shut-off valve

11. Re-open the left shut-off valve (V1) on the vacuum gauge. The cooling system is then filled.
    1. 11.1 The filling process is complete when no more coolant is drawn out of the canister.
12. Remove special tool.
13. If necessary, fill the coolant reservoir with coolant up to the maximum marking.
14. Screw on coolant reservoir cap -1-  .

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    Screwing on coolant reservoir cap

15. Install front underbody cover.

    > WM, 519219 REMOVING AND INSTALLING COVER FOR FRONT UNDERBODY

    Information 

    Never supply power to the map-controlled thermostat using the PIWIS Tester.

16. Close the service clip -2-  on the bleeder valve assembly -3-  .

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    Closing service clip on bleeder valve assembly

17. Check that the cooling system has been filled and bled correctly.
    1. 17.1 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.
    • The passenger compartment heater is warm.
    • The electric fan for engine cooling comes on.

    Information 

    Pay particular attention to the following on V6 Hybrid EU/Rest of World vehicles: 

    • It is only possible to bleed the system using the PIWIS Tester on vehicles from model year 2021. 
    • For vehicles up to model year 2020, bleed the system manually. 
18. Perform Tester routine for cooling system using the PIWIS Tester.

    > 190107 BLEEDING THE COOLING SYSTEM