Cooling System, Draining and Filling
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
•
• Refractometer (T10007)
• Drip tray (VAG 1306)
• Torque wrench (VAG 1331)
• Spring type clip pliers (VAS 5024A)
• Adapter (VAG 1274/8)
• Cooling system charge unit (VAS 6096)
Draining
- Remove front - 1 - and rear - 2 - noise insulation.
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a cloth and open carefully.
- Open cap for coolant expansion tank.
- Place drip tray for workshop crane (VAS 6208) under engine.
- Remove drain plug - 1 - at coolant thermostat housing and drain coolant.
• Ignore - item 2 -.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Disconnect lower right coolant hose - arrow - from radiator and drain coolant.
- Remove coolant hose clamps - arrows - and hoses from coolant pipes and drain remaining coolant.
Filling
CAUTION!
Only use tap water for mixing. Well water does not have the quality necessary to ensure proper coolant function.
• On vehicles from Model Year (MY) 2008, only coolant additive G 12 plus plus conforming to TL VW 774 G may be used.
• On vehicles through MY 2007, coolant additive G 12 plus conforming to TL VW 774 F and G 12 plus plus conforming to TL VW 774 G can be used.
• G 12 plus plus may be mixed with the previous coolant additive G12 plus. Both are colored purple.
• Coolant additives marked with "Conforms to TL VW 774 G" or "Conforms to TL VW 774 F" prevent freezing and corrosion damage and scaling and they increase 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 a greater frost protection is required, the amount of coolant additive of can be increased, but only up to 60% (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
• Refractometer (T10007) is recommended for determining freeze protection density.
• If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
- Install drain plug - 1 - with new seal to the coolant thermostat housing.
• Ignore - item 2 -.
- Install drain plug - arrow - with new seal to the front coolant pipe.
- Connect lower right coolant hose - arrow - to radiator.
- Install coolant hoses and clamps - arrows - to coolant pipes.
- Fill cooling system filler unit (VAS 6096) reservoir with at least 15 liters of premixed coolant with correct mixture ratio:
Recommended Mixture Ratios
* The quantity of coolant can vary depending upon the vehicle equipment.
- Attach adapter (VAG 1274/8) to coolant expansion tank.
- Install cooling system charge unit (VAS 6096) on adapter (VAG 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: 8 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 - 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 replacement reservoir (VAS 6096/1); cooling system is filled.
- Detach cooling system charge unit (VAS 6096) from adapter (VAG 1274/8) on coolant expansion tank.
- Twist expansion tank cap closed.
- Start engine.
- Set front and rear 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.
CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a cloth and open carefully.
- Check coolant level.
• Coolant level must be at MAX-marking - arrow - with engine cold.
• Coolant level may be above MAX marking with engine at operating temperature.
Tightening Specifications
