Procedures

Cooling System, Draining and Filling

Special tools, testers and auxiliary items required

• Adapter (V.A.G 1274/8)

• Adapter (V.A.G 1274/10)

• Hose Clip Pliers (V.A.G 1921)

• Cooling System Charge Unit (VAS 6096)

• Drip Tray (VAS 6208)

• Refractometer (T10007)

Draining

• Drained coolant must be stored in a clean container for disposal or reuse.


Cover the cap of the expansion tank with a rag and open carefully, as hot steam for example hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- Loosen quick-release fasteners - 1 and 2 - and remove front noise insulation.






- Place (VAS 6208) under engine.






- Remove drain plug - arrow - on the coolant thermostat housing and drain coolant from engine.

Filling

• Ignition turned off.

• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.

• Use only coolant additive Plus (G 012 A8F A1) (short: G12+) "according to TL VW 774 F". 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.

• 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. 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 down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -35 °C (-31 °F)).

• 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 (-40 °F)), otherwise frost protection and cooling effectiveness will be reduced.

• Only clean drinking water may be used for mixing coolant.

• If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant.

• Dirty coolant may not be used again.

• For coolant G12+ , use (T10007) to test frost protection in cooling system.

- Re-install drain plug - arrow - with new sealing ring.






- Fill replacement reservoir (VAS 6096/1) with at least 12 liters of pre-mixed coolant with correct mixture ratio:






• G12+ (40%) and water (60%) for freeze protection down to -25 °C (-13 °F)

• G12+ (50%) and water (50%) for freeze protection down to -35 °C (-31 °F)

• G12+ (60%) and water (40%) for freeze protection down to -40 °C (-40 °F)

- Install (V.A.G 1274/8) onto expansion tank.

- Assemble (VAS 6096) on (V.A.G 1274/8).

- 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 the lever perpendicular to direction of flow.

- Connect hose - 3 - to pressurized air.

• Pressure: 6 to 10 bar pressure.

- Open valve - B -, to do this turn 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 -, to do this turn lever in direction of flow, 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 the display instrument must remain in the green region, then the sufficient vacuum in the cooling system is obtained 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 (VAS 6096/1) ; cooling system is filled.

- Check coolant level and add coolant up to MAX-marking.






- Install (V.A.G 1274/8) onto expansion tank.






- Connect (V.A.G 1274/10) to adapter.

- Remove rubber seal for plenum chamber cover - 1 -.






- Remove plenum chamber cover - 2 - toward front.

- Open bleeder screw - arrow - in coolant hose.






- Fill up coolant until it escapes from the coolant hose bleeder screw without bubbles.

- Close coolant hose bleeder screw.

- If present, switch on auxiliary heater for about 30 seconds.

- Twist expansion tank cap closed.

- Start the engine.

- Set heating & air conditioning system to "HI" on both sides.

- Let engine run at 2000 RPM for 3 minutes.

• Heating effect must be noticeable at the latest as soon as the needle on the coolant temperature gauge moves.

- Shut off engine.

- Check coolant level.

• Coolant level may be above MAX marking with engine at operating temperature.