Cooling System, Flushing: Notes

Special tools and workshop equipment required

Coolant Flushing and Filling Device: VAS531007

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Cooling System Tester - Directional Valve: VAS691005/5

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Hose Clip Pliers: VAS6362

Fig 1: Hose Clip Pliers
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Suction jet pump from the Cooling System Charge Kit: VAS6096

Fig 2: Cooling System Charge Kit: VAS6096
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Refractometer: T10007A

Fig 3: Refractometer : T10007 A
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Compressed air connector with 6 to 10 bar (87.02 to 145.04 psi) pressure
Shop Crane - Drip Tray: VAS6208

Fig 4: Identifying Drip Tray
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Elbow Assembly Tool: T10118

Fig 5: Elbow Assembly Tool T10118
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The cooling system must 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.
Particles are visible in the coolant.
Deposits have accumulated in the coolant expansion tank.

NOTE:

Coolant has drained from flushing. Then the cooling system is filled with distilled water.

The cooling system is then flushed with approximately 20 liters of distilled water. Afterward the distilled water is replaced with coolant (mixture ratio of 50: 50).

Used coolant cannot be used again.

Schematic Overview - Coolant Flushing and Filling Device: VAS531007 :

Fig 6: Cooling System

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Reservoir with Distilled Water
- Fill with 25 liters of distilled water
Reservoir with Coolant
- Fill with at least 20 liters of coolant
- Freeze protection through approximately -36 °C (-32.8 °F)
Empty Container
- For used coolant
Empty Container
- For used coolant
Suction Hose
- Comes from the connection 2 on the viewing glass
Viewing Glass
- If colored the viewing glass must be cleaned with a nylon brush
Pump
- Cut-off pressure approximately 1.5 bar (21.76 psi)
Valve Block
- With pressure gauge and shut-off valves
Drain Hose
- Is connected to the valve block to reduce the pressure
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
Plugs
Hose Clamps
- Quantity: 4
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
Extraction Adapter
- Approximately 100 cm long
- Is connected to the suction hose -item : Suction Hose in order to extract the coolant

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.

-- Let the coolant drain in the Shop Crane - Drip Tray: VAS6208 .

-- Reconnect the removed coolant hoses.

-- Release and remove the connector -arrow- on the Engine Temperature Control Module -GX33- -3- with the ignition switched off.

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-- Use the Elbow Assembly Tool: T10118 to do this.

Coolant Flushing and Filling Device: VAS531007 , Preparing:

-- Fill the container >>1<< with at least 25 liters of distilled water.

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

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

-- Connect the battery charger. Refer to BATTERY, CHARGING .

-- 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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NOTE:

Do not connect the valve block to the Cooling System Tester - Directional Valve: VAS691005/5 yet. The filling hose must first be bled.

-- 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:

Fig 7: Identifying Coolant Reservoir Cap

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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 (-12.33 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 (-12.33 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 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. Additionally the pump moves distilled water in 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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-- Start the engine and let it run for one minute with increased speed. Then switch off the engine and begin flushing.

Cooling System, Flushing with Distilled Water

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-- 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-.

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-- 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-.

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

-- Open the shut-off valve -A- and pump approximately 20 liters of distilled water through the engine.

-- Once the 20 liters of distilled water are pumped, switch off the engine and close the shut-off valve -A-.

-- Now flush the cooling system with coolant.