Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Pipe (V.A.G 1274/10)
• Drip tray for workshop crane (VAS 6208)
• Hose clamp 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.
CAUTION!
Cover cap of 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 quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Place drip tray for workshop crane (VAS 6208) or drip tray (V.A.G 1306) under engine.
- Open drain plug - arrow - from lower left coolant hose and drain coolant.
Filling
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Only coolant additive G12+ can be used, in compliance with 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 "conforming to TL (VW 774F) " 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 for climatic reasons a greater frost protection is required, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling effectiveness is also 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 additive G12+, use refractometer (T10007 ) to test frost protection in cooling system.
- Close drain plug - arrow -.
- Fill coolant reservoir of cooling system filler unit (VAS 6096) with at least 8 liters of pre-mixed coolant with correct mixture ratio:
• G12+ (40%) and water (60%) for frost protection to -25 °C
• G12+ (50%) and water (50%) for frost protection to -35 °C
• G12+ (60%) and water (40%) for frost protection 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 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 cooling system by suction jet pump.
• Needle on instrument display must travel into green region.
- Briefly open valve - A - (lever in direction of flow), so that the hose of cooling system filler unit (VAS 6096 ) is filled with coolant.
- Close valve - A - again.
- Let valve - B - remain open another 2 minutes.
A further vacuum is created in cooling system by suction jet pump.
• Needle on instrument display must still remain in green region.
- Close valve - B -.
• Needle in display instrument must remain in green region, then sufficient vacuum in cooling system is obtained for upcoming filling.
If needle stands below green region, repeat procedure
If vacuum decreases, cooling system is leaking
- Disconnect pressurized air hose.
- Open valve - A -.
The vacuum in cooling system causes coolant to be extracted from cooling system filler unit (VAS 6096); cooling system is filled.
- Detach cooling system filler unit (VAS 6096 ) from coolant expansion tank.
- Connect adapter for cooling system tester (V.A.G 1274/10 ) to adapter (V.A.G 1274/8).
- 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 coolant hose bleeder hole without bubbles.
- Push coolant hose onto connection and secure it with spring-type clamp.
- If present, switch on auxiliary heater for about 30 seconds.
- Twist cap for expansion tank closed.
- 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.