Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Adapter for V.A.G 1274 Tester (V.A.G 1274/10)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Refractometer (T10007)
Draining
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
- Open the coolant reservoir cap.
- Remove the noise insulation - 1 - and - 2 -..
• Collect escaping coolant in a clean container for disposal or reuse.
- Place (VAS 6208) under engine.
- Remove the drain plug - arrow - on the front coolant pipe and drain the coolant.
- Remove the drain plug - arrow - on the map controlled engine cooling thermostat (F265) and drain the coolant.
- Loosen the clamp - 1 - and remove the coolant hose from the left lower coolant pipe.
• Ignore - 2 -.
Filling
• Tightening specifications, refer to => [ Coolant Pump and Coolant Thermostat Overview ] Coolant Pump and Coolant Thermostat Overview, => [ Coolant Pipes Overview ] Coolant Pipes Overview.
• Ignition switched off.
• The cooling system is filled year year-round with a mixture of water and coolant additive. Mixture ratio.
• Only use coolant according to the electronic parts catalog ETKA. 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 with the correct mixture ratio prevents freezing and corrosion damage and calcium 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 down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -35 °C (-31 °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 for climatic reasons a greater frost protection is required, the amount of coolant can be increased, but only up to 60% (frost protection to about -40 °C (-40 °F)), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
• Only use clean drinking water for mixing coolant.
• Do not use drained coolant in the following situations:
• If the radiator, heat exchanger for the heater, cylinder head, cylinder head seal or cylinder block were replaced.
• If the coolant is contaminated.
• Use the (T10007) to determine the level of freeze protection in the coolant system.
• Secure all hose connections with hose clamps appropriate for the model, refer to the electronic parts catalog ETKA.
• Replace the gasket and O-ring.
Coolant Mixture Ratio
• Coolant (40%) and water (60%) for freeze protection down to -25 °C (-13 °F)
• Coolant (50%) and water (50%) for freeze protection down to -35 °C (-31 °F)
• Coolant (60%) and water (40%) for freeze protection down to -40 °C (-40 °F)
• For the correct coolant, refer to the electronic parts catalog ETKA
Procedure
- Connect the coolant hose and clamp - 1 - to the left lower coolant pipe.
- Install the drain plug - arrow - with a new O-ring on the map controlled engine cooling thermostat.
- Install the front coolant pipe drain plug - arrow - with a new seal.
- Fill the coolant reservoir on the (VAS 6096) with at least 15 liters of premixed coolant with the proper mixture ratio.
- Attach (V.A.G 1274/8) to coolant reservoir.
- Install the (VAS 6096) on the (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 the coolant circuit valves and select 01 - Coolant Circuit Bleeding in Guided Functions, see vehicle diagnosis tester.
- 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 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 windshield wiper arms.
- Remove the seal - 1 - near the plenum chamber cover.
The plenum chamber cover could be damaged.
• Coat the bond between the windshield and the plenum chamber cover with soapy water.
- Carefully remove the plenum chamber cover - 2 - starting upward starting at the edge of the window - arrows -.
- Lift the plenum chamber cover and disengage it from the guide tabs - 4 - and then disengage it from the side covers - 3 -.
- Open the bleed screw - arrow -.
- Fill the coolant until it escapes from the coolant hose bleeder hole.
- Close the bleeder screw.
- If the vehicle has an auxiliary heater, switch it on for about 30 seconds.
- Close the cap on the coolant reservoir until it latches.
- Start the engine.
- Turn off engine and allow it to cool off.
- Install the noise insulation..
- Check the coolant level.
• With cold engine, coolant level must be at MAX marking.
• Coolant level may be above MAX marking with engine at operating temperature.
- Install the windshield wiper arms.