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)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (VAS 6362)
• Refractometer (T10007)
Draining
• Collect escaping coolant 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.
- Open coolant reservoir cap.
- Remove noise insulation.
- Place (VAS 6208) under engine.
- Remove the drain plug - 1 - and drain the coolant.
• Ignore - 2 -.
- Remove the coolant hose - arrow - from the radiator and let the coolant drain.
Filling
• Ignition switched off.
• The cooling system is filled year-round with a mixture of water and coolant additive.
• Use only the coolant additive approved for this engine. 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.
• The coolant additive prevents frost and corrosion damage as well as lime deposits. They also raise the boiling point. The cooling system must be filled with coolant additive year-round.
• 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 down to approximately -25 °C / -77 °F (in arctic climatic countries down to approximately -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%.
• When stronger freeze protection is needed due to the climate, the portion of coolant additive can be increased. It can be increased up to 60% (freeze protection down to -40 °C / -104 °F. If it is increased even more, the freeze protection and cooling effect are decreased.
• 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 reused.
• 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.
- Close the drain plug - 1 -.
• Ignore - 2 -.
- Install the coolant hose on the engine oil cooler - arrow -.
- Fill the coolant reservoir in the (VAS 6096) with 12 liters of coolant having the correct mixture ratio:
• Coolant additive (40%) and water (60%) for freeze protection down to -25 °C / -77 °F
• Coolant additive (50%) and water (50%) for freeze protection down to -35 °C / -95 °F
• Coolant additive (60%) and water (40%) for freeze protection down to -40 °C / -104 °F
• For the correct coolant additive.
- Attach (V.A.G 1274/8) to coolant reservoir.
- Install (VAS 6096) on (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 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 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 (VAS 6096) form (V.A.G 1274/8) on coolant reservoir.
- Connect the (V.A.G 1274/10) to the (V.A.G 1274/8).
- Remove the seal - 1 - and remove the plenum chamber cover - 2 -.
- Open the bleeder screw - arrow -.
- Fill the coolant until it escapes from the coolant hose bleeder hole.
- Close the bleeder screw.
- Close the cap on the coolant reservoir until it latches.
- Start engine.
- Set the temperature to "HI" for all zones and set the fan speed as low as possible.
- Switch the A/C compressor off by pressing the ECON button.
- Run engine at 2000 RPM for 3 minutes.
- Run the engine at idle until both large coolant hoses on the radiator are warm.
- Let the engine run at 2000 RPM for one 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.
- Add more coolant if necessary.