Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (V.A.G 1921)
• Cooling System Charge Unit (VAS 6096)
• Refractometer (T10007)
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.
- Open cap of coolant expansion tank.
- Remove noise insulation.
- Place the (VAS 6208) under engine.
- Drain the coolant, by pulling off the lower coolant hose - arrows -.
Filling
• The cooling system is filled year-round with a mixture of water and coolant additive. Mixture ratio.
• Only use coolant according to the electronic parts catalog ETKA. 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 with the correct mixture ratio prevents freezing and corrosion damage and calcium deposits. They also raise the boiling point. The cooling system must be filled with coolant additive year-round.
• 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℉) (in arctic climatic countries down to approximately -35 °C (-31℉).
• The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. Coolant additive portion must be at least 40%.
• If more freeze protection is needed due to the climate, increase the amount of coolant additive, but only up to 60% (freeze protection down to -40 °C (-40℉)). Otherwise the freeze protection and cooling effectiveness will be reduced.
• Only use clean drinking water for mixing coolant.
• If radiator, heat exchanger, cylinder head or head seal or cylinder block were replaced, do not reuse used coolant.
• Dirty coolant may not be used again.
• Use the (T10007) to determine the level of freeze protection in the coolant system.
- Push the lower coolant hose onto the radiator - arrow -.
- Fill coolant reservoir of (VAS 6096) with at least 8 liters of pre-mixed coolant with correct mixture ratio.
Coolant Mixture Ratio
• Coolant (40%) and water (60%) for freeze protection down to -25 °C (-13℉)
• Coolant (50%) and water (50%) for freeze protection down to -35 °C (-31℉)
• Coolant (60%) and water (40%) for freeze protection down to -40 °C (-40℉)
• Coolant, refer to the electronic parts catalog ETKA
- Install (V.A.G 1274/8) on expansion tank.
- Assemble the (VAS 6096) on the (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 - (lever perpendicular to direction of flow).
- Connect hose - 3 - to pressurized air.
• Pressure: 6 to 10 bar pressure
- Open 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.
- Briefly open valve - A - (lever in direction of flow), so that the hose of the (VAS 6096) is filled with coolant.
- Close valve - A - again.
- Let valve - B - remain open for 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 causes coolant to be extracted from the (VAS 6096) ; cooling system is filled.
- Check coolant level and add coolant up to max-marking.
- Start engine, allow it to run at approximately 1500 RPM for a max. of 2 minutes and fill coolant up to overflow hole of expansion tank.
- Close expansion tank.
- Allow engine to run until fan turns on.
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.
- Check coolant level and fill if necessary. With engine at operating temperature, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.
- Shut off engine.