Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Adapter V.A.G 1274 Tester (V.A.G 1274/10)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (VAS 6362)
• Refractometer (T10007)
Draining
• 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 for example hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove noise insulation.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Open drain plug - 1 - and allow coolant to drain.
• Ignore - 2 -.
- Disconnect coolant hose - arrow - from engine oil cooler and drain remaining coolant.
Filling
• Ignition switched off.
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Only use one of the frost and corrosion additives approved for this vehicle. Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage.
• Frost and corrosion protection additives prevent freezing and corrosion damage and scaling. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives.
• Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
• Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).
• 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 increased freeze protection is needed because of the climate, the amount of G12+ can be increased, but only up to 60% to provide freeze protection to about -40 °C. Otherwise the freeze protection and cooling effectiveness will be reduced.
• Only use clean drinking water for mixing coolant.
• Do not use drained coolant in the following situations:
• If the radiator, oil cooler, heat exchanger, cylinder head, cylinder head seal or cylinder block were replaced.
• If the coolant is contaminated.
• Secure all hose connections with hose clamps appropriate for the model.
• Use the Refractometer (T10007) to determine the level of freeze protection in the coolant system.
- Close drain plug - 1 -.
• Ignore - 2 -.
- Connect coolant hose to engine oil cooler - arrow -.
- Fill Replacement Reservoir (VAS 6096/1) with at least 12 liters of pre-mixed coolant with correct mixture ratio:
• Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -25 °C.
• Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection down to -35 °C.
• Coolant freeze and corrosion protection additive (60%) and water (40%) for freeze protection down to -40 °C.
• Coolant freeze and corrosion protection additive.
- Place air outlet hose - 1 - into a small container - 2 -. (A small amount of coolant is drawn off which should be reserved with the discharged air.)
- 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 pressure.
- Open valve - B -, turn lever in direction of flow to do this.
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 -, turn lever in direction of flow to do this, so that hose of the Replacement Reservoir (VAS 6096/1) 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 display must remain in green region, then vacuum in cooling system is sufficient for subsequent 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 Coolant Reservoir (VAS 6096/1); cooling system is filled.
- Remove Cooling System Charge Unit (VAS 6096) from coolant expansion tank.
- Connect Adapter for VAG1274 Tester (V.A.G 1274/10) to Adapter (V.A.G 1274/8).
- Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.
- Open bleeder screw - arrow -.
- Fill up coolant until it escapes from the coolant hose bleeder hole.
- Close the bleeder screw.
- If present, switch on auxiliary heater for about 30 seconds.
- Twist cap for expansion tank closed.
- Start engine.
- Adjust the temperature for all zones to "HI".
- Switch the A/C compressor off by pressing the ECON button.
- Let engine run at 2000 RPM for 3 minutes.
- Let engine run at idle long enough until both large coolant hoses on main cooler are warm.
- Let engine run at 2000 RPM for 1 minute.
- Turn off engine and allow it to cool off.
- Check coolant level.
• With cold engine, coolant level must be at MAX marking.
• Coolant level may be above MAX marking with engine at operating temperature.