Pour in coolant and bleed engine cooling system

AR20.00-W-1142-03H

Pour in coolant and bleed engine cooling system

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Model

963, 964 with engine 470.9, 471.9, 473.9, 936.9

Connect vacuum-type cooling system filler (1)

1

Set heating to max. heating output and switch on ignition.

2

Switch off auxiliary heater.

3

Only on vehicles with code B3H (Secondary Water Retarder)
Set retarder to the fifth brake stage.

4

Check all hoses and connections on the  vacuum-type cooling system filler (1) for leak tightness and damage.

 The  vacuum-type cooling system filler (1) and the engine cooling system must be free of leaks for optimum filling.

5

 Attach vacuum-type cooling system filler (1) near the expansion reservoir and close all shutoff valves (1.1, 1.2, 1.3).

6

Screw the  adapter with a yellow mark onto the expansion reservoir.

7

Put filling hose (1.4) onto  adapter.

8

Let the other end of the filling hose (1.4) hang into a container containing clean coolant.

 During the entire filling process, the coolant level must remain above the suction opening. The quality of the filling will be reduced significantly if air is drawn in.

9

Connect the compressed-air hose (2) of the workshop connection to the  vacuum-type cooling system filler (1).

 The pressure of the workshop connection must be at least 6 bar. If the pressure of the workshop connection is less than 6 bar, the required vacuum may not be achieved in certain situations.

Generate vacuum

10

Open shutoff valves (1.1) and (1.2) until a vacuum of -0.8 bar is achieved in the engine cooling system.

 If the coolant is drawn out of a container that is placed on the floor, the vacuum should not be greater than -0.8 bar. If it is greater, there is a danger that the engine cooling system could be overfilled. If the container is placed in the pit, the vacuum should be increased to -0.9 bar. If the vacuum decreases visibly, the  vacuum-type cooling system filler (1) and the engine cooling system must be checked for leak tightness.

11

Pre-fill the filling hose (1.4) up to the shutoff valve (1.3) with coolant by opening the shutoff valve (1.3) slightly.

12

After a vacuum of -0.8 bar/-0.9 bar has been achieved, first close shutoff valve (1.2) and then shutoff valve (1.1).

Filling

13

Open shutoff valve (1.3).

 This starts the filling, and the coolant is drawn into the engine cooling system. Filling is complete when no more coolant is draw in. The entire filling process lasts about 7 minutes.

If the entire filling process lasts more than 8 minutes,



remove filter (1.5) and clean it.

14

Open shutoff valve (1.2) and drain the coolant out of the filling hose (1.4).

15

 Remove vacuum-type cooling system filler (1).

16

Start the engine, increase the engine speed to about 1,600 rpm, and hold it at that engine speed.

 If accessibility is good, the engine speed can also be increased using the external engine start/stop and engine stop (S600) on the side of the engine. Never raise the driving level if accessibility is poor.
A crushing hazard arises if this is done.

17

While maintaining the elevated engine speed, refill coolant up to the lower edge of the filler neck until the coolant level in the expansion reservoir no longer drops.

 To avoid having coolant slosh out of the filler neck, do not reduce/lower the engine speed until the cap is fully tightened.

18

Tighten the cap.

19

Switch off engine.

 The engine cooling system is under pressure. Do not open the cap until after an operating day with coolant temperatures  90 °C, the retarder has been used, and a cooling off phase.