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
• 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 i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove quick-release fasteners - 1 -, remove screws - 2 - and remove noise insulation.
- Place drip tray for workshop crane (VAS 6208) under engine.
- Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.
Filling
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Use only coolant additive Plus (G 012 A8F A1) (short: "G12+") "according to 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.
• "G12+" and coolant additives with the designation " according 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 for climatic reasons greater frost protection is required, 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.
- Re-install drain plug - arrow - with new sealing ring.
- Fill coolant reservoir of Cooling System Charge Unit (VAS 6096) with at least 12 liters of pre-mixed coolant with correct mixture ratio:
• "G12+" (40%) and water (60%) for freeze protection down to -25 °C
• "G12+" (50%) and water (50%) for freeze protection down to -35 °C
• "G12+" (60%) and water (40%) for freeze protection down to -40 °C
- Screw adapter (V.A.G 1274/8) onto 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 the discharged air.)
- Close both valves - A - and - B -, turn lever perpendicular to direction of flow to do this.
- 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 coolant reservoir hose of the 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 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 coolant reservoir of (VAS 6096); cooling system is filled.
- Detach cooling system filler unit (VAS 6096 ) from adapter (V.A.G 1274/8) on coolant expansion tank.
- Connect pipe for cooling system tester (V.A.G 1274/10) to adapter.
- Remove plenum chamber cover rubber seal.
- Remove plenum chamber cover - 1 - toward front - arrows -.
- Slide back boot for coolant hoses at connection of heater core.
- 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 without bubbles.
- Push coolant hose on connection and tighten.
- Twist cap for expansion tank 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 may be above MAX marking with engine at operating temperature.
Tightening Specifications
