Filling Up Coolant

Information 

• The amount of coolant available must be approx. 2 litres 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 I, 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). 

Information 

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

Information 

• 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. Install lower cap -1-  on radiator -3-  .

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   Lower cap on radiator

   1. 1.1  Push lower cap -1-  onto radiator -3-  .
   2. 1.2  Press spring clamp -2-  down to lock the locking mechanism.
2. Set up and connect vacuum filling device.

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   Illustration of vacuum-filling device set-up

   1. 2.1  Fill coolant reservoir -5-  with at least 12 litres of pre-mixed coolant in the correct mixture ratio.
   2. 2.2  Screw cap adapter K65 -6-  for the coolant reservoir onto the coolant reservoir.
   3. 2.3  Connect the flexible extension (FZ 100) to the cap.
   4. 2.4  Connect vacuum gauge -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 a 90° angle to the flow direction 

   5. 2.5  Connect the Venturi nozzle to vacuum gauge -7-  .
   6. 2.6  Push the filler hose of vacuum gauge -7-  onto the canister connection.
   7. 2.7  Route return line -1-  from the Venturi nozzle to a second container -2-  .
   8. 2.8  Connect compressed air supply -4-  to filler hose -3-  .
   9. 2.9  Build up overpressure from 6 to 10 bar.
3. Open both shut-off valves -V1 and V2-  on the vacuum gauge until the transparent filler hose has completely filled with coolant.

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   Shut-off valve open

4. Close left shutoff valve (V1) -Arrow-  on the vacuum gauge and allow a vacuum to build up in the coolant circuit.

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   Shut-off valve on filler hose closed

5. Allow a sufficient vacuum to build in the cooling system (pointer is in the green area) > Vacuum built up (pointer in green area). 

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   Vacuum built up (pointer in green area)

6. Close right shut-off valve (V2) -Arrow-  and disconnect the compressed air supply. Open the left shut-off valve (V1) on the vacuum gauge again. The cooling system is then filled.

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   Filling the cooling system - shut-off valve for filler hose open

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). > Right shut-off valve open 

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   Right shut-off valve open

8. Remove the complete filling tool (including adapter K65).
9. Push pipe -1-  > V. A. G 1274/10 - Pipe for cooling system tester  onto adapter -2-  > V. A. G 1274/8 - Adapter for cooling system tester  .

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   Tester

10. Fill up coolant as far as required until pipe for cooling system tester > V. A. G 1274/10 - Pipe for cooling system tester  is full.
11. For vehicles with auxiliary heating, switch this on and leave it running for about 30 seconds.
12. Close coolant reservoir cap -1-  .

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    Coolant reservoir cap

13. Switch to position "P", start the engine and let it warm up.
14. Switch on passenger compartment heating.
15. Press the "Sport button". Leave "Sport" mode activated during the bleeding process.
16. Check the following during the warm-up phase:
    1. 16.1  Coolant temperature and engine oil temperature in the instrument cluster.

       Duration	Engine speed	Conditions
       3 minutes	2, 000 rpm	With air conditioning "Off" Heater "HI"
       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.
    • The passenger compartment heater is warm.
    • The electric fan for engine cooling comes on.
18. Correct level:
    • The fill level in the coolant reservoir must be at the MAX marking when the engine is cold.
    • The fill level in the coolant reservoir can be above the MAX marking when the engine is at operating temperature.

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    Coolant reservoir fill level