Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Adapter V.A.G 1274 Tester (V.A.G 1274/10)
• Hose Clamp Pliers (V.A.G 1921)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray for Workshop Crane (VAS 6208)
• Refractometer (T10007)
Draining
• Collect escaping coolant in a clean container for disposal or reuse.
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• To reduce pressure, cover coolant reservoir cap with cloth and carefully open.
- Open coolant reservoir cap.
- Remove front noise insulation - 1 -.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Remove drain plug - 1 - and drain the coolant.
• Ignore - 2 -.
- Remove coolant hose - arrow - from the oil cooler and let the coolant drain.
Filling
• Ignition switched off.
• 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.
• Freeze protection must be guaranteed to about -25 °C (to about -35 °C in countries with extremely cold climates).
• 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. 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, heat exchanger, cylinder head or cylinder head seal or cylinder block were replaced.
• If the coolant is contaminated.
• Dirty coolant must not be re-used.
• Secure all hose connections with hose clamps appropriate for the model.
• Use the Refractometer (T10007) to determine the level of freeze protection in the coolant system.
- Close drain plug - 1 -.
• Ignore - 2 -.
- Install coolant hose on the oil cooler - arrow -.
- Fill coolant reservoir on (VAS 6096) with at least 12 liters of premixed coolant with the proper mixture ratio:
• Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -25 °C.
• Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection down to -35 °C.
• Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -25 °C.
• For coolant freeze and corrosion protection additive.
- Attach Adapter (V.A.G 1274/8) to coolant reservoir.
- Install the Cooling System Charge Unit (VAS 6096) on the Adapter (V.A.G 1274/8).
- Place air outlet - 1 - in a small container - 2 -.
• A small amount of coolant which should be collected is drawn off with the discharged air.
- Close valves - A - and - B - by turning lever at a right angle to direction of flow.
- Connect hose - 3 - to compressed air.
• Pressure: 6 to 10 bar pressure.
- Open valve - B - by turning level in direction of flow.
• The suction jet pump generates pressure in the coolant system; indicator on display instrument must move into green area.
- Briefly open valve - A - by turning lever in direction of flow so that hose on (VAS 6096) coolant reservoir fills with coolant.
- Close valve - A - again.
- Leave valve - B - open another 2 minutes.
• More pressure is generated in the coolant system by the suction jet pump; indicator on display instrument must stay in green area.
- 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 area, repeat procedure.
• If pressure falls, check coolant system for leaks.
- Remove pressurized air hose.
- Open valve - A -.
• Coolant is extracted from the (VAS 6096) coolant reservoir by pressure in the coolant system and the system is filled.
- Remove Cooling System Charge Unit (VAS 6096) form Adapter (V.A.G 1274/8) on coolant reservoir.
- Connect Tube (V.A.G 1274/10) to the Adapter (V.A.G 1274/8).
- Remove the center piece - 2 - or the entire plenum chamber cover, depending on the version.
- Loosen coolant hose to the heat exchanger and pull it back until the bleeder hole - arrow - in the coolant hose is no longer covered by the connection.
- Fill the coolant until it escapes from the coolant hose bleeder hole.
- Slide the coolant hose onto the connection and secure with a spring clamp.
- If the vehicle has an auxiliary heater, switch it on for about 30 seconds.
- Close coolant reservoir cap.
- Start engine.
- Set the temperature to "HI" for all zones and set the fan speed as low as possible (0).
- Switch the A/C compressor off by pressing the AC button.
• The LED in the button must not come on.
- Run engine at 2000 RPM for 3 minutes.
- Run the engine at idle until both large coolant hoses on the radiator are warm.
- Run engine at 2000 RPM for 2 minutes.
- Turn off engine and allow it to cool off.
- Install front noise insulation.
- 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.