Draining and Filling, High Temperature Coolant Circuit
Draining and Filling, High Temperature Coolant Circuit
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant expansion tank cap with a cloth and then open it slowly to release the pressure in the system.
=> [ Draining the Radiator ]
=> [ Draining the Engine/Heater Circuit ]
=> [ Filling ]
Draining the Radiator
Special tools, testers and auxiliary items required
• Drip Tray for VAS 6100 (VAS 6208)
The coolant system must be drained if larger components (for example, engine, radiator, etc.) are going to be removed and installed. Refer to => [ Draining the Engine/Heater Circuit ]. Otherwise an incorrect filling will result due to air bubbles in the system. The cooling and heating systems will have temperature problems.
- Remove the noise insulation.
- Place the drip tray for VAS 6100 (VAS 6208) under the engine.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the coolant expansion tank cap.
- Remove the quick release - arrow - on the bottom right side of the radiator.
- Reposition the clamp - arrow -, remove the coolant hose from the oil cooler and allow the coolant to drain.
Draining the Engine/Heater Circuit
Special tools, testers and auxiliary items required
• Spring-Type Clip Pliers (VAS 6499)
• Drip Tray for VAS 6100 (VAS 6208)
• 20 mm Diameter Hose Extension
• Compressed Air Gun
- Drain the radiator. Refer to => [ Draining the Radiator ].
- Close the coolant expansion tank cap.
- Remove the left front wheel.
- Remove the left front wheel housing liner..
Draining the Engine Coolant Pipes:
- Open the clamps - A and B - and remove the coolant hoses.
- Attach a hose - 2 - to the pipe - B - to lengthen it and place the other end in the drip tray for VAS 6100 (VAS 6208).
- Apply maximum of 1 bar compressed air across the hose - A - using a compressed air gun - 1 - until the circuit is completely empty.
Draining the Heater Coolant Pipes:
- Attach a hose - 1 - to the pipe - A - to lengthen it and place the other end in the drip tray for VAS 6100 (VAS 6208).
- Apply maximum of 1 bar compressed air across the hose - B - using a compressed air gun - 2 - until the circuit is completely empty.
- Connect the coolant hoses and the position the clamps.
Filling
Special tools, testers and auxiliary items required
• Refractometer (T10007 A)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6340)
• Cooling System Charge Unit (VAS 6096)
• Adapter (V.A.G 1274/8)
Do not mix distilled water with coolant additives. Using distilled water provides optimum corrosion protection
• The water portion of the coolant influences the effectiveness of the coolant. Volkswagen has decided to define the water quality used in the cooling system based on the different mixtures and country and regional requirements. Use distilled water.
• Use only coolant additives listed in the Parts Catalog. 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. The boiling point will be raised. 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.
• Freeze protection must be guaranteed 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 a lower freeze protection is necessary due to the climatic conditions, increase the amount of coolant additive. Only up to 60% (freeze protection down to approximately -40 °C (-40 °F)). Otherwise the freeze protection and cooling effect are reduced.
• Do not use the old coolant again if replacing the radiator, heater core, cylinder head or cylinder head gasket.
• The refractometer (T10007 A) is recommended for determining freeze protection density.
- Fill the coolant reservoir for the cooling system charge unit (VAS 6096) with at least 15 liters of premixed coolant with the proper mixture ratio:
• Coolant additive (40%) and distilled water (60%) for freeze protection down to -25 °C (-13 °F).
• Coolant additive (50%) and distilled water (50%) for freeze protection down to -35 °C (-31 °F).
• Coolant additive (60%) and distilled water (40%) for freeze protection down to -40 °C (-40 °F).
• For the correct coolant additive, refer to the Parts Catalog.
- Install the adapter (V.A.G 1274/8) onto the coolant expansion tank.
- Install the cooling system charge unit (VAS 6096) to the adapter (V.A.G 1274/8).
- Close the levers - A and B - by turning them at a right angle to the direction of flow.
- Place the hose - 1 - in a small container - 2 -.
• A small amount of coolant which should be collected is drawn off with the discharged air.
- Connect the hose - 3 - to compressed air.
• Pressure: 6 to 10 bar pressure.
- Open the lever - B - by turning it in the direction of flow.
• At least 0.7 bar vacuum must be produced.
- Briefly open the lever - A - by turning it in the direction of flow so that the hose on the cooling system charge unit coolant reservoir fills with coolant.
- Close the lever - A - again.
- Leave the lever - B - open another 2 minutes.
• A further vacuum is created in the cooling system by the suction jet pump.
- Close the lever - B -.
- Remove the pressurized air hose.
- Watch the pressure gauge. The vacuum may go down only to 0.4 bar. Check the coolant system for leaks if the vacuum continues to fall.
• The cooling system does not have any leaks if the vacuum falls but then stabilizes at minimum 0.4 bar.
• Perform the next filling "slowly".
- Open the lever - A - slowly.
• Coolant is extracted from the cooling system charge unit coolant reservoir by pressure in the coolant system and the system is filled.
- Remove the cooling system charge unit (VAS 6096) from the adapter (V.A.G 1274/8) on the coolant expansion tank.
- Check the coolant level in the expansion tank and fill it up or siphon it out, as necessary.
- Check the coolant concentration. Refer to => [ Coolant Concentration, Checking ] Coolant Concentration, Checking.