Cooling System, Flushing: Procedure:

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- With the coolant hose removed, pour approximately one liter distilled water in the coolant expansion tank.

-- Allow the coolant to drain into the Drip Tray.

-- Reconnect the removed coolant hoses.

:VAS531007 Preparing:

-- Fill the container >>1<< with 30 liters (8 gallons) of distilled water.

-- Fill the container >>2<< with 30 liters (8 gallons) of coolant. Mixture ratio 50:50 approximately -36 °C (-32.8 °F).

-- Drain the container >>3<< and >>4<<.

-- Remove the valve block from the connector coupling on the equipment trolley,

-- Connect the :VAS531007 to the battery.

:VAS531007 bleeding:

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-- Connect the suction hose -A- to the reservoir >>1<< with distilled water.

-- Connect the drain hose -arrow- on the connector coupling -B- on the valve block.

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-- Close the shut-off valves -A and B-.

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NOTE:

Do not connect the valve block to the :VAS691005/5 yet. The filling hose must first be bleed,

-- Switch on the pump for the Coolant Flushing and Filling Device :VAS531007 .

-- Open the shut-off valve -A-.

-- Quickly open the shut-off valve -B- so that the filling hose is bleed.

-- Close the shut-off valves -A and B- again.

Coolant Flushing and Filling Device:VAS531007 Connecting:

Fig 1: Identifying Coolant Reservoir Cap

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-- Open the coolant reservoir cap -arrow-.

-- Install the test adapter -2- (:VAS691005/5 ) on the coolant expansion tank -1-.

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-- Remove the drain hose -arrow- from the connector coupling -B- on the valve block.

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-- Connect the valve block -1- on the test adapter -2-.

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-- Connect the suction jet pump -2- from the :VAS6096 to the connector coupling -B- on the valve block -1-.

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Fill the Cooling System with Distilled Water:

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-- Place the drain hose -8- from the suction jet pump in a container.

-- Connect the pressure hose -6- on the suction jet pump -7-.

-- Open the shut-off valve -B- on the valve block -5-.

A further vacuum is created in the cooling system by the suction jet pump. The needle on the pressure gauge must lower to a minimum - 0.85 bar (-12 PSI).

-- Close the shut-off valve -B-.

-- Remove the pressure hose -6-.

-- Watch the pressure gauge. The needle on the pressure gauge must stay at a minimum - 0.85 bar (-12 PSI). Only then is there enough vacuum in the coolant system for the filling.

NOTE:

Check the cooling system for leaks if the pressure drops.

The vacuum required depends on the pressure in the pressure air system.

The pump from the :VAS531007 must be switched on.

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-- >>Slowly<< open the shut-off valve -A-.

The distilled water is extracted and the cooling system is filled via the vacuum in the cooling system. Additionally the pump from the :VAS531007 pushes distilled water in the coolant expansion tank.

-- Fill the cooling system until approximately 1 bar (14.5 psi) pressure is displayed.

After filling the pressure must be removed from the coolant expansion tank. Proceed as follows:

-- Close after filling the shut-off valve -A-.

-- Remove the suction jet pump -2- from the valve block -1-.

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-- Connect the drain hose -arrow- to the connector coupling. Open the shut-off valve -B- and leave it open, so that the pressure in the cooling system builds.

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-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

Fig 2: Identifying Engine Coolant Temperature Sensor

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-- Release and disconnect the connector -1- from the Engine Coolant Temperature Sensor -G62- -3-, with the ignition switched on.

NOTE:

When the connector is removed from the Engine Coolant Temperature Sensor -G62- the Engine Temperature Control Actuator -N493- is opened when the engine starts and the radiator fan starts running.

-- Install the air filter housing temporary so that the room remains free on the cylinder head. The air filter housing can for example be laid on the battery.

-- Start the engine and let it run for one minute with increased speed. Then switch off the engine.

Flushing the Cooling System with Distilled Water:

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Shut-off valve -A- closed, and shut-off valve -B- opened.

-- Remove the bleeder hose -2- from the coolant expansion tank -1-.

-- Connect the bleeder hose -2- from the coolant expansion tank with the flushing hose -1-.

-- Seal the connection on the coolant expansion tank using the plugs -3-. Secure the plug with a hose clamp.

-- Close the shut-off valve -B-.

NOTE:

The cooling system will be flushed. Pay attention to the fill level of the reservoir to maintain the flushing volume.

The engine runs at idle during the entire flushing procedure.

-- Start the engine and let it run in idle.

-- Set the heater temperature to "HI".

-- Press the AC button to turn off the A/C compressor.