Cooling System, Flushing: Notes

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Special Tools And Workshop Equipment Required 

• Coolant Flushing and Filling Device:VAS531007 
• Cooling System Tester - Directional Valve:VAS691005/5 
• Hose Clip Pliers:VAS6362 
• Shop Crane - Drip Tray:VAS6208 
• 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
• Elbow Assembly Tool:T10118 

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.
• Strong 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 30 liters (8 gallons) of distilled water
   • From this 19 liters (5 gallons) will be required for flushing
   • 11 liters (3 gallons) serve as security reserve and remain in the canister
2. Reservoir with Coolant
   • Fill with 30 liters (8 gallons) of coolant
   • Freeze protection through approximately -36 °C (-32.8 °F), (mixture ratio 50:50)
   • From this 18 liters (5 gallons) will be required for flushing
   • 12 liters(3 gallons) serve as security reserve and remain in the canister
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 10-  COOLING SYSTEM, FLUSHING - Flushing Hoses
14. Extraction Adapter
    • Approximately 100 cm long
    • Is connected to the suction hose -item 5-  COOLING SYSTEM, FLUSHING - 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 (1 quart) distilled water in the coolant expansion tank.

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

-- Reconnect the removed coolant hoses.

Coolant Flushing and Filling Device: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 containers >>3<< and >>4<<.

-- 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:

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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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 psi). Only then is there enough vacuum in the coolant system for the filling.

• 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. The pump for the :VAS531007  also moves the distilled water into the coolant expansion tank.

-- Fill the cooling system until approximately 1 bar pressure is displayed.

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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-- 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 off.

-- Temporarily install the air filter housing so that the space on the cylinder head remains accessible. 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.

Cooling System, Flushing 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-.

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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 in idle.

-- Set the heater temperature to "HI".

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