Draining Off and Filling With Coolant
Draining off and filling with coolant
Special tools and equipment
^ Adapter V.A.G 1274/8
^ Tubular section V.A.G. 1274/10
^ Drip tray V.A.G. 1306
^ Hose clamp pliers V.A.G 1921
^ Cooling system filler VAS 6096 with VAS 6096/1
^ Refractometer T1 0007
Draining off
Note: Coolant drained off must be collected in a clean container for disposal/re-use.
WARNING: Hot vapor/hot coolant may escape when opening expansion tank. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly
- Unscrew cap of coolant expansion tank.
- Unfasten quick-release fasteners -1- and -2- and remove front noise insulation. Leave rear noise insulation in position.
- Position drip tray VAG 1306 beneath engine.
- Remove drain plug (arrow) at thermostat housing and drain off coolant at engine.
Filling
Note:
^ The cooling system is filled all year round with a mixture of water and radiator anti-freeze/anti-corrosion agent
^ Exclusive use is to be made as coolant additive of G12+ as per TL VIN 774 F. Other coolant additives could considerably impair anticorrosion action. The result could lead to loss of coolant and could damage the engine.
^ Coolant additive G 12+ can be mixed with additives G11 and G 12.
^ "G 12" and coolant additives according to specification TL VIN 774 F" prevent frost and corrosion damage, stop scaling and raises the the boiling point of the coolant. For these reasons the cooling system must be filled all year round with the correct anti-freeze and anticorrosion additive.
^ Because of the higher boiling point, the coolant improves engine reliability under heavy loads particularly in countries with tropical y climates.
^ Protection against frost must be assured to about -25°C (43°F), in arctic climatic countries to about -35°C (-31°F).
^ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40%.
^ If greater frost protection is required in very cold climates, the amount of G 12 can be increased, but only up to 60% (this gives frost protection to around -40°C) otherwise frost protection decreases again and cooling efficiency is impaired.
^ Use clean drinking water for mixing coolant.
^ Always replace coolant after replacing, heat exchanger, cylinder head, cylinder head gasket or cylinder head. Do not re-use old coolant.
^ Never re-use contaminated coolant.
^ Use special tool T40007 to check frost protection of coolant additive "G 12 "in cooling system.
- Install drain plug (arrow) with new sealing ring.
- Fill coolant tank using VAS 6096/1 with at least 12 liters of pre-mixed coolant in the correct mixture ratio.
^ 12 (40%) and water (60%) for frost protection down to -25°C
^ 12 (50%) and water (50%) for frost protection down to -35°C
^ 12 (60%) and water (40%) for frost protection down to -40°C
- Screw adapter V.A.G. 1274/8 onto coolant expansion tank.
- Mount cooling system filler VAS 6096 on adapter V.A.G. 1274/8.
- Hold air discharge hose -1- over a small vessel 2-.
^ A small quantity of coolant is entrained in the air discharged and is to be collected.
- Close both valves -A- and -B- (lever at right angles to direction of flow).
- Connect hose -3- to compressed air supply.
^ Pressure: 6 to 10 bar
- Open valve -B- (lever in direction of flow).
^ The suction jet pump generates a vacuum in the cooling system
^ Pointer of indicator must move into green zone
- Briefly open valve -A- (lever in direction of flow) to fill hose of coolant tank VAS 6096/1 with coolant.
- Close valve -A- again.
- Leave valve -B- open for another 2 minutes.
^ The suction jet pump continues to generate vacuum in the cooling system
^ Pointer of indicator must remain in green zone
- Close valve -13,
^ Pointer of indicator must settle in green zone; vacuum in cooling system is then sufficient for subsequent filling
^ Repeat procedure if pointer is below green zone
^ Decrease in vacuum indicates leak in cooling system
- Detach compressed air hose.
- Open valve -A,
^ The vacuum in the cooling system causes coolant to be drawn out of the coolant tank VAS 6096/1; the cooling system is filled
- Check coolant level and pour in coolant as far as MAX mark.
- Screw adapter V.A.G. 1274/8 to coolant expansion tank.
- Attach special tool V.A.G 1274/10 to adapter.
- Remove plenum chamber cover rubber seal in direction of (arrow).
- Remove plenum chamber cover -1- to front.
- Remove coolant hose (arrow) to heating system heat exchanger and pull it back until vent hole in coolant hose is no longer covered by connection.
- Pour in coolant until there are no bubbles in coolant emerging from vent hole in coolant hose.
- Attach coolant hose to connection and tighten.
- Briefly open bleeder screw (arrow) at left auxiliary radiator until coolant emerges.
- Close bleeder screw by hand.
- Briefly open bleeder screw (arrow) at right auxiliary radiator until coolant emerges.
- Close bleeder screw by hand.
- Top off coolant if necessary and seal expansion tank.
- Set passenger compartment temperature to "HI".
- Start engine and let it warm up.
^ Heating action must become apparent at the latest when the coolant temperature gauge needle starts to move
- Switch engine off.
- Check coolant level.
^ Coolant level may be above MAX mark when engine is warm