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Additive container: suction off and replenish with new additive
Protection measures and rules of conduct when working on the additive container - system
  WARNING
For all tasks, pay attention to the following points:
t  The additive is harmful to your health.
t  Read the safety instructions on the container of the new additive!
t  Information about storage and disposal → safety data sheets for additive!
t  Information about „risks for humans and the environment“, „protection and hygiene measures“, „behaviour in case of danger “ → safety data sheets for additive.
t  The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the connections of the additive container in order to extract the released additive gases, even before the work is commenced.
t  If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m3/h must be used.
t  Safety googles and fuel-resistant gloves must be worn during assembly work on the additive container system (avoid skin contact with the additive)!
t  Assembly work on the open system must only be carried out in well-ventilated areas!
t  Do not inhale the additive vapours!
t  Keep the additive away from heat, sparks and open fire.
t  The vapours of the additive can form an explosive mixture with air.
t  Vapours are heavier than air and if there is contact with the ground they can become sources of ignition.
t  The additve must not reach into the piping and ground area. Immediately tie up and eliminate visible leaks.
t  The additive container is pressurized! Before opening the system place a cloth around the connecting points and reduce the pressure by carefully slackening the connecting points!
t  Collect the additive which flows out in a vessel, e.g. if the lines are loose!
t  Route all types of lines e.g. fuel lines, additive lines as well as electrical wirings in such a way that the original wiring is re-established.
t  Ensure that there is adequate free access to all moving or hot components.
General points
  Note
t  The additive container with its connections is located in the spare wheel well.
t  The additive container has a capacity of 4.0 liters.
t  Use new additive only.
t  The 1.0 liter can has the part number -G 052 143 A2-.
t  A display lights up in the dash panel insert if the remaining capacity is below 0.3 liters of the additive container.
Remove sealing connector
–  Remove spare wheel.
    
–  Remove both caps of the additive container -arrows-.
  Note
Safety precautions when working on the additive container must be observed!
   N01-10214
–  First remove the sealing connector from the ventilation -arrow A-
–  Then remove the sealing connector from the suction / filling -arrow B-
–  Before opening the system place a cloth around the connecting points and reduce the pressure by carefully slackening the connecting points!
   N01-10215
Detach sealing connector as follows:
-Arrow A- round connector side.
-Arrow B- flat connector side.
–  Push-in circlip onto the round side of the connector -arrow A-, by hand or using a suitable tool und release the connector.
   N01-10226
Connections of the fuel additive container
Ventilation -arrow A- (small connection diameter).
Suction/filling -arrow B- (large connection diameter).
Suction off additive and top up
Special tools and workshop equipment required
t  Extraction and filling device -z. B. VAS 6277-
t  Hose clamp -MP7-602 (3094)-
Suction off additive:
  Note
Observe operating instructions for extraction device -VAS 6277-. -VAS 6277-.
   N01-10215
–  Place connector -4- of extraction device onto the connection for suctioning / filling, corresponding connections → Anchor.
–  Connect the compressed air supply -2- with the extraction device.
–  Suction off additive by carefully pulling on the dosing lever -3-.
  WARNING
t  Align the ventilation -1- in direction of the well-ventilated areas; do not inhale expelling gases.
t  Observe that the suction reservoir of the extraction device is not overfilled during the the suctioning. There is a risk of overflow.
t  Terminate the suctioning procedure, if the container is filled up to about two-third, see -arrow 5-.
t  If necessary repeat the suctioning procedure.
t  Do not use again suctioned (used) additive.
t  Dispose of suctioned (used) additive according to the operating instructions.
–  If the entire additive is suctioned, the compressed air supply has to be separated.
Replenish with additive:
   S02-0489
–  Screw the original container of the new additive -1- with the filling device.
–  Connect the filling device and the overflow protection with the connections -arrow 3- and -arrow 4- to the corresponding connections → Anchor.
–  Additionally attach a hose clamp to the end of the hose for the filling device.
  Note
After the filling procedure and when detaching the hose, the hose clamp should prevent that the additive remaining in the filling hose flows out.
–  Open the valve -2- and let the additive (4 x 1.0 ltr. - can) run into the additive container until the fluid in the hose is visible by the overflow protection.
The additive container has a capacity of 4.0 liters.
   S02-0490
–  Close the valve -2- and disconnect the filling hose to the hose clamp.
   S02-0490
–  Disconnect the filling device and the overflow protection from the connections of the additive container -arrows A + B-.
–  Place both sealing connectors onto the connections.
   N01-10215
–  Install both caps of the additive container -arrows-.
–  Install the spare wheel.
Concluding operations
–  Unscrew the additive container from the filling device.
–  Empy the filling device so that no remaining additive remains in the hose or in the shut-off valve.
  Note
The remaining additive cristalizes in combination with oxygen.
  WARNING
Cristalized additive can lead to malfunctions in the additive system.
If necessary eliminate excess additive with absorbing, non-burning material (bonding material).
Dispose of the materials, which are impregnated with the additive, e.g. with a cloth or bonding material, in a suitable sealed container, observe regulations regarding risk of poisoning!
–  Replenish the empty original containers of the new additive with suctioned additive. Observe regulations regarding the risk of poisoning!
  WARNING
Additive should always be stored in the original container in a dry and well-ventilated area.
   N01-10214


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