Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Drip tray (V.A.G 1306) or drip tray (VAS 6208)
• Hose clamp pliers (V.A.G 1921)
• Cooling system charge unit (VAS 6096)
• Refractometer (T10007)
Draining
- Activate the vehicle lifting mode.
• Drained coolant must be stored in a clean container for disposal or reuse.
- Remove cover above coolant reservoir - arrows -.
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 fasteners - 1 - and remove front noise insulation.
- Place drip tray (V.A.G 1306) or drip tray (VAS 6208) under engine.
- Disconnect coolant hose - arrow - from left coolant pipe and drain coolant.
- Remove lower right coolant hose from auxiliary cooler - arrow - and allow remaining coolant to drain.
Filling
CAUTION!
• Refilling the cooling system must be performed exclusively using the cooling system charge unit (VAS 6096). Otherwise, automatic transmission malfunctions could occur.
• 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.
• Freeze protection 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 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.
• 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.
Conditions
• Ignition switched off.
Procedure
- Connect lower right coolant hose to auxiliary cooler - arrow -.
- Connect lower coolant hose to coolant pipe - arrow -.
- Fill replacement reservoir (VAS 6096/1) with at least 15 liters of pre-mixed coolant with correct mixture ratio:
• "G12+" (40%) and water (60%) for freeze protection down to -25° C.
• "G12+" (50%) and water (50%) for frost protection down to -35° C.
• "G12+" (60%) and water (40%) for frost protection down to -40° C.
- Install adapter (V.A.G 1274/8) on expansion tank.
- Assemble Cooling System Charge 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 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.
- Remove rubber seal - 1 - for plenum chamber covers.
- Remove plenum chamber cover - 2 -.
• Ignore - 3 -.
- Open bleeder screws - arrows -.
- Fill up coolant until it escapes from the bleeder holes in the coolant hoses.
- Close bleeder screws.
- Twist cap for expansion tank closed.
- Make sure that the auxiliary heater is switched off.
- Start engine.
- Set heating & air conditioning system to "HI" on both sides.
- 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.
- Deactivate vehicle lifting mode.