26/11/2024 07:36:51

Cooling System - Vacuum Refill

Correction Code 18300400

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Warning
Wear appropriate personal protective equipment (PPE) including a full face mask when performing this procedure.
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CAUTION
Incorrect use of the Vacuum Refill Tool can result in rupture of the cooling system and possible flooding of High Voltage components.
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CAUTION
Use the specified coolant only. In this manual, refer to Fluids.
Informational PurposesAn informational icon, calling your attention
Note
Make sure at least 14 L of the specified coolant is available before beginning this procedure.
  • 2024-11-26: Added images of vacuum refill tool setup and added warning on incorrect use of the refill tool.

Refill

  1. Remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  2. Remove the HEPA filter housing. See Housing - Filter (Remove and Replace).
  3. Remove the coolant reservoir cap.
  4. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  5. Unlock the vehicle gateway. See Gateway Unlock.
  6. In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, click PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain, under Action, select Start, under Fluid Fill Target, select Coolant, click Run, and allow the routine to complete.
  7. Install the reservoir adapter to the coolant reservoir.
  8. Attach the reservoir adapter to the vacuum refill tool.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test to verify that the hose is fully installed.
  9. Ensure that the coolant refill valve and the air inlet valve are closed.
    1 Coolant refill hose
    2 Coolant refill valve
    3 Air inlet valve
    4 Shop air supply
    5 Overflow hose
  10. Position a container of coolant at, or as close as possible to, the height of the coolant reservoir.
    Informational PurposesAn informational icon, calling your attention
    Note
    The container should be filled with at least 14 L of the specified coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use the specified coolant only. See Fluids.
  11. Place the end of the coolant refill hose into the coolant container. Ensure that the end is fully submerged.
    Tip: If the container is especially deep, the end of the hose might float in the coolant. Use a weight, hanger, or other tool to keep the end of the hose submerged in the coolant.
  12. Position an empty coolant collection container near the coolant supply container.
  13. Insert the coolant overflow hose into the coolant collection container.
  14. Connect shop air supply with a minimum pressure of 5.5 bar (80 PSI) to the vacuum refill tool.
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, verify that the refill valve is set to off.
  15. Open the air inlet valve.
    Informational PurposesAn informational icon, calling your attention
    Note
    A hissing noise is normal.
  16. Allow the tool to evacuate the system until the needle on the vacuum gauge reaches the green range or the needle stops moving.
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    Note
    It is normal for some cooling hoses to collapse due to the vacuum in the system.
  17. Close the air inlet valve and monitor the gauge for approximately 30 seconds to verify that a vacuum is maintained in the cooling system.
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    Note
    If the gauge reading drops, there is a leak in the system that must be fixed before refilling with coolant.
  18. Very slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose. Close the valve when the hose is full of coolant. This purges trapped air from the hose.
  19. Reopen the air inlet valve. Close the valve when the vacuum gauge needle stops rising.
  20. Slowly open the coolant refill valve to allow coolant to be drawn into the system.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Ensure that the end of the coolant refill hose remains submerged to prevent air from being drawn into the system. Immediately close the coolant refill valve if air enters the coolant refill hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the hose end of refill hose is fully submerged during entire process.
  21. Once the gauge stops moving, close the coolant refill valve.
  22. Remove the vacuum refill tool:
    1. Leave the coolant refill hose in the container.
    2. Lift the tool from the reservoir.
    3. Holding the tool above the container, open the coolant refill valve to drain the coolant from the refill hose into the container.
  23. Ensure that the coolant refill valve and the air inlet valve are closed.
  24. Disconnect the reservoir adapter from the vacuum refill tool.
  25. Remove the vacuum refill tool and hoses from the vehicle.
  26. Remove the reservoir adapter from the coolant reservoir.
  27. Remove the coolant supply container and coolant collection container from the vehicle.
  28. In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, click PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain, under Action, select Stop, under Fluid Fill Target, select Coolant, click Run, and allow the routine to complete.
  29. In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Coolant Air Purge, and click Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The coolant air purge routine runs for approximately 15 minutes and the coolant level in the reservoir may drop. If the level has stabilized and does not drop further, the routine can be ended early.
  30. Monitor the coolant level and add coolant as needed so that the coolant level remains at the "MAX" line.
    Informational PurposesAn informational icon, calling your attention
    Note
    The coolant level should stabilize before the routine ends. If the coolant level is still dropping, perform the routine again.
  31. Make sure that the coolant level is at the "MAX" line.
  32. Install the coolant reservoir cap.
  33. Perform a cooling system thermal test. See Cooling System - Thermal Test.
  34. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  35. Install the HEPA filter housing. See Housing - Filter (Remove and Replace).
  36. Install the HEPA filter. See Filter - HEPA (Remove and Replace).