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. 

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. 

Information 

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

Information 

New pressure gauge display for > 9696 - filling device 

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Pressure gauge display on filling device 9696

• Green area -1-  : vacuum range without electric vacuum pump. 
• Blue area -2- : vacuum range with electric vacuum pump. 

1. Connect compressed air supply to compressed air connection -3-  .

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   Compressed air supply connection

   1. 1.1  Screw cap adapter KS 65 -6-  onto the coolant reservoir.
   2. 1.2  Connect the flexible extension (FZ 100) to the cap.
   3. 1.3  Close shut-off valves -V1-  and -V2-  (90° with respect to flow direction).
   4. 1.4  Connect the vacuum gauge -7-  of the bleeder tool to the flexible extension (FZ 100).
   5. 1.5  Connect Venturi nozzle to the vacuum gauge -7-  .
   6. 1.6  Place the filling canister -5-  beside the vehicle, close to the coolant reservoir.
   7. 1.7  Push 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-  .
   8. 1.8  Connect the compressed air supply.
2. Open the shut-off valves on the vacuum gauge until the filler hose is completely filled with coolant. > Shut-off valves 

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   Shut-off valves

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

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   Shut-off valve on filler hose

4. When there is a sufficient vacuum in the cooling system (indicator is in the green area), close the right shutoff valve (V2) and then disconnect the compressed air supply.

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   Right shut-off valve

   1. 4.1 To check the system for leaks, a constant vacuum must be present for 30 seconds! 
5. > VAS 6096/2 - Vacuum pump -3-  must be connected to the Venturi nozzle and to the 12 V battery or battery charger.

   Do not use electric vacuum pump for more than 3 minutes! 

   Fig 1: Vacuum Pump VAS 6096/2 With Venturi Nozzle Components Location

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   Vacuum pump VAS 6096/2 with Venturi nozzle

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

   1. 5.1  > VAS 6096/2 - Vacuum pump -3-  must be switched on. Then open the shut-off valve at the Venturi nozzle for the pump connection.
   2. 5.2 Check the amount of coolant in the overflow tank -4- while using the electric vacuum pump! 
   3. 5.3  Close the shut-off valve at the Venturi nozzle after 3 minutes and switch off the > VAS 6096/2 - vacuum pump  .
   4. 5.4  Disconnect connecting hose -2-  from the > VAS 6096/2 - vacuum pump  to the Venturi nozzle.
6. Check that the vacuum in the system remains constant.

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   Pressure gauge display after using the vacuum pump

   1. 6.1  Check the pressure gauge display: The pointer -1-  on the pressure gauge -2-  should be approx. 5 mm below the end mark of the blue area -Arrow-  .
   2. 6.2  Check the system for leaks: Build up a vacuum in the cooling system and leave it for 30 seconds. 
7. Fill the cooling system.

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   9696 - Filling device

   1. 7.1  Open the shut-off valve -V1-  to the canister on the vacuum gauge -1-  again in order to fill the cooling system.
   2. 7.2  Wait until there is no longer a vacuum or until coolant is no longer drawn out of the canister.
   3. 7.3  Open the shut-off valve -V1-  to the Venturi nozzle.
8. > 9696 - Filling device  must now be removed from the coolant reservoir.
9. Check the coolant level in the coolant reservoir and correct it to the maximum  level if necessary.
10. Close the cap on the coolant reservoir.