Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (V.A.G 1921)
• Cooling System Charge Unit (VAS 6096)
• Refractometer (T10007)
• Adapter V.A.G 1274 Tester (V.A.G 1274/10)
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
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.
- Remove front noise insulation by loosening fasteners - 1 -.
• Ignore - 2, 3 and 4 -.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Remove drain plug - 1 - on Map Controlled Engine Cooling Thermostat (F265) and allow coolant to drain.
• Ignore - 2 -.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
Filling
• Tightening specifications. Refer to => [ Coolant Pump and Coolant Thermostat Assembly Overview ] Coolant Pump and Coolant Thermostat Assembly Overview, => [ Coolant Pipes Assembly Overview ] Coolant Pipes Assembly Overview.
• Ignition switched off.
• 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.
• Coolant additive "G12+" can be combined with additives "G11" and "G12".
• "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.
• Do not reuse contaminated coolant.
• For coolant "G12+" , use Refractometer (T10007) to test frost protection in cooling system.
- Install drain plug - 1 - with new O-ring on Map Controlled Engine Cooling Thermostat (F265).
• Ignore - 2 -.
- Reinstall drain plug - arrow - with new gasket at front coolant pipe.
- Fill coolant reservoir of Cooling System Charge Unit (VAS 6096) with at least 15 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 -40.00° C
- Attach Adapter (V.A.G 1274/8) to coolant expansion tank.
- Install 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 - by turning lever perpendicular to direction of flow.
- Connect hose - 3 - to pressurized air.
• Pressure: 6 to 10 bar 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 - by turning lever in direction of flow so that Cooling System Charge Unit (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 display must remain in green region, then vacuum in cooling system is sufficient for subsequent 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 Charge 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 rubber seal - 1 - for plenum chamber covers.
- 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.
- If present, switch on auxiliary heater for about 30 seconds.
- Twist cap for expansion tank closed.
- Start engine.
- Set left and right 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 must be at "MAX" marking with engine cold.
• Coolant level may be above "MAX" marking with engine at operating temperature.