Cooling System, Flushing: Notes

Special Tools And Workshop Equipment Required 

• Coolant Flushing and Filling Device :VAS531007 
• Cooling System Tester - Directional Valve :VAS691005/5 
• Hose Clip Pliers :VAS6362 
• Suction jet pump from the Cooling System Charge Kit :VAS6096 
• Refractometer :T10007A 
• Compressed air connector with 6 to 10 bar (87.02 to 145.03 psi) pressure
• Two hose clamps up to 25 mm

After replacing the following components the cooling system must be flushed:

• Cylinder Head
• Heater Core for the Heater
• Radiator
• Charge Air Cooling Circuit Cooler
• Intake Manifold with Charge Air Cooler

Old coolant is replaced with new coolant during the flushing procedure. This ensures the optimal surface protection of the new components.

The Cooling System Must Also Be Flushed If the Following Abnormalities Occur:

• The coolant has either developed a more intense color or become discolored.
• The coolant has an unnatural or unusual odor.
• Pericles are visible in the coolant.
• Deposits have accumulated in the coolant expansion tank.

Schematic Overview - Coolant Flushing and Filling Device:VAS531007  :

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1. Reservoir with Distilled Water
   • Fill with 20 liters (5.28 gallons) of distilled water
2. Reservoir with Coolant
   • Fill with at least 20 liters (5.28 gallons) of coolant
   • Freeze protection up to approximately -36 °C (-32.8 °F)
3. Empty Container
   • For used coolant
4. Empty Container
   • For used coolant
5. Suction Hose
   • Comes from the connection 2 on the viewing glass
6. Viewing Glass
   • If colored the viewing glass must be cleaned with a nylon brush
7. Pump
   • Cut-off pressure approximately 1.5 bar (21.75 psi)
8. Valve Block
   • With pressure gauge and shut-off valves
9. Drain Hose
   • Is connected to the valve block to reduce the pressure
10. Flushing Hoses
    • Is connected for flushing on the coolant expansion tank bleeder hose
    • Comes from the connection 1 on the viewing glass
    • If not used seal with plugs
11. Plugs
12. Hose Clamps
    • Quantity 4
13. Cleaning Adapters
    • Approximately 15 cm long
    • For cleaning the Coolant Flushing and Filling Device after flushing
    • Is connected between the valve block and the flushing hose -item  ) Flushing Hoses-.
14. Extraction Adapter
    • Approximately 100 cm long
    • Is connected to the suction hose -item  ) Suction Hose in order to extract the coolant

Coolant Flushing and Filling Device:VAS531007  , Preparing:

-- Fill the container >>1<< with at least 20 liters (5.28 gallons) of distilled water.

-- Fill the container >>2<< with at least 20 liters (5.28 gallons) of coolant. Mixture ratio 50:50 approximately -36 °C (-32.8 °F).

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

-- Connect the battery charger.

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

-- Connect the Coolant Flushing and Filling Device:VAS531007  to the battery.

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

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

-- Briefly open the shut-off valve -B- so that the filling hose is bled.

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

Coolant Flushing and Filling Device: VAS531007  , Connecting:

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-- Open the coolant reservoir cap -arrow-.

-- Install the test adapter -2- (Cooling System Tester - Directional Valve: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 Cooling System Charge Kit:VAS6096  to the connector coupling -B- on the valve block -1-.

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Cooling System, Filling 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 (-12.32 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 (-12.32). Only then is there enough vacuum in the coolant system for the filling.

• The pump from the Coolant Flushing and Filling Device: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. The pump for the Coolant Flushing and Filling Device:VAS531007  also moves the distilled water into the coolant expansion tank.
• After filling, the coolant expansion tank must be depressurized. 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 reduces.

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