Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Refractometer (T10007)
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
- Remove cover above coolant reservoir - arrows -.
CAUTION!
Cover the coolant reservoir cap with a cloth and open carefully because steam or hot coolant may escape when opening.
- Open the cap on the coolant reservoir.
- Open the quick-release fasteners - 1 - and remove the front noise insulation.
- Place (VAS 6208) under engine.
- Remove drain plug - arrow - at coolant thermostat housing and drain coolant.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Remove lower coolant hose - 2 - from right auxiliary cooler and drain remaining coolant.
• Ignore - 1 -.
Filling
• Ignition switched off.
CAUTION!
Refilling the cooling system must be performed exclusively using the (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.
• Only use one of the frost and corrosion additives approved for this vehicle. 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.
• Frost and corrosion protection additives prevent freezing and corrosion damage and scaling. 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 (-77° F) (in arctic climatic countries to about -35° C (-95° 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 increased freeze protection is needed because of the climate, the amount of G12+ can be increased, but only up to 60% to provide freeze protection to about -40° C (-104° F). Otherwise the freeze protection and cooling effectiveness will be reduced.
• Only use clean drinking water for mixing coolant.
• Do not use drained coolant in the following situations:
• If the radiator, oil cooler, heat exchanger, cylinder head, cylinder head seal or cylinder block were replaced.
• If the coolant is contaminated.
• Secure all hose connections with hose clamps appropriate for the model.
• Use the (T10007) to determine the level of freeze protection in the coolant system.
- Reinstall drain plug - arrow - with new O-ring at coolant thermostat housing.
- Reinstall drain plug - arrow - with new gasket at front coolant pipe.
- Install lower coolant hose - 2 - on right auxiliary cooler - arrow -.
- Fill coolant reservoir in the (VAS 6096) with at least 15 liters of pre-mixed coolant to the correct mixture ratio:
• Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -25° C (-77° F).
• Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection down to -35° C (-95° F).
• Coolant freeze and corrosion protection additive (60%) and water (40%) for freeze protection down to -40° C (-104° F).
- Install the adapter (V.A.G 1274/8) in the coolant reservoir.
- Install (VAS 6096) on (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.
• 6 to 10 bar positive pressure.
- Open valve - B -, to do this turn 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 briefly open valve - A - by turning lever in direction of flow so that (VAS 6096) coolant reservoir hose 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 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; cooling system is filled.
- Remove the (VAS 6096) from the (V.A.G 1274/8) on the coolant reservoir.
- Remove rubber seal - 1 - and 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.
- Close the coolant reservoir cap.
- If present, switch on auxiliary heater for about 30 seconds.
- Start engine.
- Adjust the temperature for all zones to "HI".
- Switch the A/C compressor off by pressing the ECON button.
- 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.
Tightening Specifications
