Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (VAG1274/8)
• Adapter For VAG1274 Tester (VAG1274/10)
• Drip Tray For VAS6100 (VAS6208) or (V.A.G 1306)
• Hose Clip Pliers (VAG1921)
• Cooling System Charge Unit (VAS6096)
• Refractometer (T10007)
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
Cover cap of coolant expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.
- Loosen screws or quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Place Drip Tray For VAS6100 (VAS6208) under engine.
Vehicles with coolant drain plug:
- Open coolant drain plug - 2 - at cooler, position assisting hose on support, if necessary, and drain coolant.
Vehicles without coolant drain plug:
- Remove retaining clip at Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) - 3 -.
- Remove Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) from supports and drain coolant.
All:
- Also disconnect coolant hose at oil cooler - arrow - and let rest of coolant drain.
Filling
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Only coolant additive Plus (G 012 A8F A1) (short: " G12+") "conforming to TL VW 774 F" may be used. 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 " conforming 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 (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 greater frost protection is required for climatic reasons, 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.
• Replace seals and O-rings.
• Secure all hose connections using hose clamps appropriate for the model type.
Vehicles with coolant drain plug:
- Close coolant drain plug on coolant line at bottom of cooler.
Vehicles without coolant drain plug:
- Insert Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) - 3 - with new O-ring in connection and secure with retaining clip.
All:
- Install coolant hose to oil cooler - arrow -.
- Fill coolant reservoir of Cooling System Charge Unit (VAS6096) with at least 12 liters of pre-mixed coolant with correct mixture ratio:
• "G12+" (40%) and water (60%) for frost 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.
- Thread Adapter (VAG1274/8) onto coolant expansion tank.
- Assemble Cooling System Charge Unit (VAS6096) on Adapter (VAG1274/8).
- 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 positive 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 (VAS6096/1) 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 is obtained 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 Replacement Reservoir (VAS6096/1); cooling system is filled.
- Disconnect Cooling System Charge Unit (VAS6096 ) from coolant expansion tank.
- Connect Adapter For VAG1274 Tester (VAG1274/10 ) to Adapter (VAG1274/8).
- Pull off rubber seal of plenum chamber cover in direction of - arrow -.
- Remove plenum chamber cover - 1 - toward front.
- Pull front engine cover off - arrows -.
- Remove bleeder screw - arrow -.
- Fill coolant until it escapes from coolant pipe bleeder hole.
- Tighten bleeder screw to 15 Nm.
• Replace seal.
- Loosen coolant hose to heater core and pull back hose sufficiently so that the bleeder hole - arrow - is no longer sealed by the connection.
- Fill up coolant until it escapes from the coolant hose bleeder hole.
- Push coolant hose onto connection and secure it using the spring-type clamp.
- On a vehicle equipped with auxiliary heater, switch it on for approx. 30 seconds.
- Twist expansion tank cap 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 cooler are warm.
- Let engine run at 2000 RPM for 1 minute.
- Turn off engine and allow it to cool off.
- Check coolant level.
• Coolant level must be at MAX-marking with engine cold.
• Coolant level may be above MAX-marking with engine at operating temperature.
Tightening Specifications
