Additive Container, Extracting Fluid and Filling with New Additive
Additive Container, Extracting Fluid and Filling with New Additive
Additive Reservoir System Safety Precautions
CAUTION!
• Diesel additive is harmful to health.
• Read safety precautions on the container of new additive.
• Information about storage and disposal can be found in ServiceNet.
CAUTION!
• Refer to ServiceNet for information about "Dangers for humans and environment", "Protection and hygiene measures", "Behavior in the case of danger".
• Before beginning work, place exhaust hose (shop exhaust system) in area of the connections to the additive container so that excess additive vapors can be extracted.
• If shop exhaust system is not available, a fan (motor located outside of the air flow) with an air flow rate of at least 15m 3/h can be used.
Always wear safety goggles and fuel-resistant gloves (avoid skin contact with additive) for all procedures on the additive container system!
Always work on open system in well ventilated areas only!
Do not inhale additive vapors!
Keep additive away from heat, sparks and open flames.
Fluid vapors can form a combustible mixture with the air.
Vapors are heavier than air and can spread at ground level toward ignition sources.
Diesel additive must not be released into sewage network or soil. Immediately absorb inadvertent leakage and remove.
Additive container is under pressure! Before opening the system, wrap a rag around the connection point and release the pressure by carefully loosening the connection point!
Catch any escaping fluid, e.g. if lines run dry, in a container!
Route lines of all types, e.g. fuel lines, additive lines as well electrical wires so that the original routing path is restored.
Make sure there is sufficient clearance to all moving or hot components.
• The connections for the additive container are located behind the cover for the tank connection.
• The additive container has a filling capacity of 4.0 liters.
• Only use new fluid.
• The 1.0 L container's part number is (G 052 143 A2).
• If there is less than 0.3 liters of additive left in the container, a warning lamp lights up in the instrument cluster.
Removing Connector Plugs
- Flip open the tank filler door and unscrew the gas cap.
- Hook the gas cap - 2 - onto the top of the tank filler door.
The connections for the additive container system are located behind the cover - 1 -.
- Carefully pull the cover out of the mounting - arrow -.
• The cover is now only connected to the drain hose.
- Turn the cover - B - on the drain hose connection - C - approximately 90 degrees counter-clockwise so that the connections become visible.
The connections find themselves on the fuel filler tube - arrow A -.
• Always observe safety precautions for working on additive containers!
- Pull the connection plug off from the VENTILATION - arrow B - connection (smaller connection diameter).
- Remove connector from the EXTRACTING/FILLING - arrow A - connection (larger connection diameter).
- Before opening the system, wrap a rag around the connection point and release the pressure by carefully loosening the connection point.
Remove connector plug as follows:
- Arrow A - Round side of the connector.
- Arrow B - Flat side of the connector.
- Install securing ring by hand or with a suitable tool at the round side of the connector - arrow A -, and pull off connector.
Fuel Additive Reservoir Connections
VENTILATION - arrow B - (smaller connection diameter).
EXTRACTING/FILLING - arrow A - (larger connection diameter).
Fluid, Extracting And Filling
Special tools, testers and auxiliary items required
• Extraction device (VAS 6277/1)
• Filling device (VAS 6277/2)
• Overflow protection (VAS 6277/3)
• Hose clip (3094)
Extracting Fluid:
• Observe operating instructions for Extraction device (VAS 6277/1)!
- Install connector - 4 - of the extraction device (VAS 6277/1) on the connection for EXTRACTION/FILLING, corresponding connections.
- Connect compressed air supply - 2 - with extraction device (VAS 6277/1).
- Extract fluid by pulling carefully on the metering lever - 3 -.
CAUTION!
• Arrange the ventilation - 1 - toward a well ventilated area. Do not inhale the escaping gases.
• During extraction, make sure the extraction container is not overfilled by the extraction device (VAS 6277/1). There is a risk of overflowing.
• Stop the extraction procedure when the container is approximately 2/3 full. refer to - arrow 5 -.
• Repeat the extraction procedure if necessary.
• Do not reuse extracted (used) additive fluid.
• Dispose of extracted (used) additive fluid according to operating instructions. Refer to ServiceNet.
- When fluid has been totally extracted, disconnect the compressed air supply.
Filling-Up with Fluid:
- Connect container of new additive fluid - 1 - to filling device (VAS 6277/2).
- Attach the filling device (VAS 6277/2) and the overflow protection (VAS 6277/3) with the connections - 3 - and - 4 - to the corresponding connections.
- Fasten the filling device (VAS 6277/2) to the end of the hose using a hose clamp (3094).
• The hose clamp is to prevent excess fluid in the filling hose from escaping when disconnecting the hose after the filling procedure.
The additive container has a filling capacity of 4.0 liters.
- Open the valve - 2 - and allow the fluid (4 x 1.0L bundle) to drain into the additive container.
• The system must not be overfilled.
• If overfilled, fluid will become visible at hose of overfill protection (VAS 6277/3).
- Close valve - 2 - and clamp off the filling hose e.g. with hose clamp (3094).
- Disconnect the filling device (VAS 6277/2) and the overflow protection (VAS 6277/3) from the additive container connections, - arrows A + B -.
- Connect both connector plugs to connections.
- Reinstall cover - 1 -.
- Close fuel filler tube with gas cap.
- Disconnect container of additive fluid from filling device (VAS 6277/2).
- Let filling device (VAS 6277/2) run empty so that no fluid remains in the hose or in the shut-off valve.
• Residual fluid crystallizes when in contact with oxygen.
CAUTION!
Crystallized fluid can lead to malfunctions in the additive system.
CAUTION!
Catch any fluid that may escape with an absorbent, non-combustible material (bonding agent).
Dispose of any materials soaked with fluid, e.g. rags or bonding agents, in a suitable, sealable container. Observe precautions for dangerous materials!
- If the fluid is extracted from the additive container system, drain the used fluid from the extraction device (VAS 6277/1) into the empty original container of the new fluid. Observe precautions for dangerous materials!
CAUTION!
Additive fluid should always be stored in the original container in a dry and well ventilated area.