Procedures
Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (VAG 1274/8)
• Drip tray for VAS 6100 (VAS 6208)
• Cooling system charge unit (VAS 6096)
• Replacement reservoir (VAS 6096/1)
• Refractometer (T10007)
• Adapter for VAG 1274 tester (VAG 1274/10)
Draining
• Before raising the vehicle on a hoist (wheels off the ground), activate the vehicle lift mode.
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
Cover the expansion tank cap with cloth and open carefully, as hot steam and/or hot coolant may escape when opening.
- Remove the coolant expansion tank cap.
- Loosen the noise insulation fasteners - 1 - and remove the noise insulation.
- Place the (VAS 6208) under the engine.
- Disconnect the coolant hose - 1 - in order to drain the coolant.
- Remove the drain plug - 2 - at the oil filter housing and drain the coolant from the right side of the engine.
- Remove the drain plug - arrows - and drain coolant from the pipe on the left side of the engine.
Filling
• 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 to about -25° C (-13° 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 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 must not be re-used.
• For coolant G12+ , use refractometer (T10007) to test frost protection in cooling system.
• Replace the seal.
• Secure all hose connections using hose clamps appropriate for the model type.
- Connect the coolant hose - 1 -.
- Install the drain plug - 2 - to the oil filter housing with new gasket on the right side of the engine.
- Install the drain plug - 2 - to the pipe on the left side of the engine.
- Fill the (VAS 6096/1) with at least 14 liters of premixed coolant with the 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 the (VAG 1274/8) onto the expansion tank.
- Install the (VAS 6096) onto the (VAG 1274/8).
- Place the air outlet hose - 1 - into a small container - 2 -.
• A small amount of coolant is drawn off with the discharged air which should be collected.
- Close both valves - A and B - (lever perpendicular to direction of flow).
- Connect the hose - 3 - to pressurized air.
• Pressure: 6 to 10 bar pressure
- Open the valve - B - (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, open valve - A - briefly (lever in direction of flow) so that hose of the (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 the needle is below the green region, repeat procedure.
• If the vacuum decreases, cooling system is leaking.
- Disconnect the pressurized air hose.
- Open valve - A -.
• The vacuum in the cooling system has the effect of extracting coolant from the (VAS 6096/1) so that the cooling system is filled.
- Remove the (VAS 6096) from the coolant expansion tank.
- Install the (VAG 1274/10) to the (VAG 1274/8).
- Remove the rubber seal - 1 - for the plenum chamber cover.
- Remove the plenum chamber cover - 2 -.
- Open the bleeder screws - 1 and 2 -.
- Fill up coolant until it leaks from the bleeder screws - 1 and 2 - without bubbles.
- Close the bleeder screws.
- Install the expansion tank cap.
- Set interior temperature to "HI".
- Let engine run at 2000 RPM for 3 minutes.
- Let engine run at idle long enough until both large coolant hoses are warm.
- Let engine run at 2000 RPM for 1 minute.
- Turn off engine and allow it to cool off.
- Check the coolant level.
• On a cold engine, the coolant level must be at the MAX mark.
• Coolant level may be above MAX mark with the engine at operating temperature.