Coolant, Draining and Refilling
Coolant, draining and refilling
Special tools, testers and auxiliary items required
^ Adapter V.A.G 1274/8
^ Adapter V.A.G 1274 tester V.A.G 1274/10
^ Drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208
^ Hose clamp pliers V.A.G 1921
^ Cooling system filler unit VAS 6096
^ Refractometer T10007
Draining
Note: Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Loosen quick-release screws - 1 -, remove screws - 2 - and remove sound insulation.
- Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
- Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.
Filling
Note:
^ The cooling system must be filled year round with frost and corrosion protection additives.
^ Only coolant additive Plus G 012 A8F A1 (short: G12+) "according to TL VW 774 F" may be used. Other coolant additives may reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage.
^ Coolant additive G12+ can be combined with additives G11 and G12.
^ G12+ and coolant additives with the designation "according to TL VW 774 F" reduce frost and corrosion damage as well as lime deposits. They also raise the boiling point. Therefore, the cooling system must be filled year round with frost and corrosion protection additives.
^ A higher boiling point improves engine reliability under heavy load particularly in countries with tropical climates.
^ Frost protection additives protect against frost to about -25°C (about -35°C in arctic climates).
^ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%.
^ If for climatic reasons greater frost protection is required, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40°C), otherwise frost protection and cooling effectiveness will be reduced.
^ Use only clean drinking water for mixing with the coolant.
^ If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant.
^ Dirty coolant cannot be reused.
^ For coolant G12+, use refractometer T10007 to test frost protection in cooling system.
- Re-install drain plug - arrow - with new seal.
- Fill coolant reservoir of cooling system filler unit VAS 6096 with at least 12 liters of pre-mixed coolant with correct mixture ratio:
^ G12+ (40%) and water (60%) for frost protection up to 25°C
^ G12+ (50%) and water (50%) for frost protection up to -35°C
^ G12+ (60%) and water (40%) for frost protection up to -40°C
- Screw adapter V.A.G 1274/8 onto expansion tank.
- Assemble cooling system filler unit VAS 6096 on adapter V.A.G 1274/8.
- Place air outlet hose - 1 - into a small container - 2 -. (A small amount of coolant is drawn off with discharged air and this should be collected.)
- Close both valves - A - and - B - by turning lever perpendicular to direction of flow.
- Connect hose - 3 - to pressurized air.
^ Pressure: 6 to 10 bar positive pressure.
- Open valve - B - by turning lever in direction of flow.
A vacuum is created in the cooling system by the suction jet pump.
^ Needle on the instrument display must travel into the green region.
- Also briefly open valve - A - by turning lever in direction of flow, so that coolant reservoir hose of cooling system filler unit VAS 6096 is filled with coolant.
- Close valve - A - again.
- Let valve - B - remain open another 2 minutes.
^ A further vacuum is created in the cooling system by the suction jet pump.
^ Needle on the instrument display must still remain in the green region.
- Close valve - B -.
^ Needle in the display instrument must remain in the green region to ensure sufficient vacuum in the cooling system for the upcoming filling.
If needle stands below the green region, repeat procedure.
If the vacuum decreases, cooling system is leaking.
- Disconnect pressurized air hose.
- Open valve - A -.
The vacuum in the cooling system has the effect of extracting coolant from the coolant reservoir VAS 6096/1; cooling system is filled.
- Remove cooling system filler unit VAS 6096 from adapter V.A.G 1274/8 on coolant expansion tank.
- Connect pipe for cooling system tester V.A.G 1274/10 to adapter.
- Remove rubber seal for plenum chamber cover.
- Remove plenum chamber cover - 1 - toward front - arrows -.
- Slide back boot for coolant hoses at connection of heater core.
- Loosen coolant hose to heater core and pull back hose sufficiently so that bleeder hole - arrow - is no longer sealed by connection.
- Fill up coolant until it escapes from coolant hose bleeder hole without bubbles.
- Push coolant hose on connection and tighten.
- Twist cap for expansion tank closed.
- Start engine.
- Set heating air conditioning system to "HI".
- Let engine run at 2000 RPM for 3 minutes.
- Let engine run at idle long enough until both large coolant hoses on main radiator are warm.
- Let engine run at 2000 RPM for 1 minute.
- Turn off engine and allow it to cool.
- Check coolant level.
^ Coolant level may be above MAX. marking with engine at operating temperature.
Tightening torque
