Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Adapter (V.A.G 1274/10)
• Cooling System Charge Unit (VAS 6096)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Refractometer (T10007)
Draining
• Collect escaping coolant in a clean container for disposal or reuse.
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, to do this loosen the fasteners - 1, 2, arrow -.
- Place (VAS 6208) under engine.
- Open the drain plug - 1 - and drain the coolant.
• Ignore - 2 -.
- Remove the coolant hose - arrow - from the radiator and let the coolant drain.
- Remove the coolant hoses from the left front coolant pipes; loosen the hose clamps - arrows - and letting the remaining coolant drain out.
• Ignore - 1 -.
• The installation location is shown with the lock carrier removed.
Filling
• Ignition switched off.
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Only use one of the frost and corrosion additives approved for this vehicle. 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. It also raises the boiling temperature. 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 (-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. Coolant additive portion must be at least 40%.
• If increased freeze protection is needed because of the climate, the amount of G12+ can be increased, but only up to 60% to provide freeze protection to about -40 °C (-40 °F). Otherwise the freeze protection and cooling effectiveness will be reduced.
• Only use clean drinking water for mixing coolant.
• Only reuse drained coolant if the radiator, the heater heat exchanger, cylinder head, cylinder head gasket or cylinder block were not replaced.
• Dirty coolant may not be used again.
• 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 -.
- Install the coolant hose on the engine oil cooler - arrow -.
- Connect the coolant hoses to the left front coolant pipes - arrows -.
- Fill coolant reservoir on the (VAS 6096) with 2 liters of premixed coolant with the proper mixture ratio:
• Coolant additive (40%) and water (60%) for freeze protection down to -25 °C (-13 °F)
• Coolant additive (50%) and water (50%) for freeze protection down to -35 °C (-31 °F)
• Coolant additive (60%) and water (40%) for freeze protection down to -40 °C (-40 °F)
- Attach the (V.A.G 1274/8) to coolant reservoir.
- Install the (VAS 6096) on adapter.
- 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 the (VAS 6096) from the (V.A.G 1274/8) on coolant reservoir.
- Mount the (V.A.G 1274/10) on the adapter.
- Fill the coolant until the coolant system tester tube is full. Fill again during the bleeding procedure if necessary.
- Remove the seal - 1 - and remove the plenum chamber cover - 2 -.
- Open the bleeder screw - arrow - until coolant starts to come out.
- Close the bleeder screw.
- Remove the rear engine cover - 2 - upward.
• Lay a cloth below to catch escaping coolant.
- Open the bleeder screws - 1 - and - 2 - one after the other until coolant starts to come out.
- Close the bleeder screw.
- Remove the lock carrier cover.
- Open the bleeder screw - arrow - until coolant starts to come out.
- Close the bleeder screw.
- Close coolant reservoir cap.
- Start the engine.
- Adjust the temperature for all zones to "HI".
- Switch the A/C compressor off by pressing the ECON or AC button, depending on the version.
• If it is the ECON button: the LED must illuminate
• If AC button: the LED must not come on.
- Run the engine at 2000 RPM for 3 minutes.
- Run the engine at idle until both large coolant hoses on the radiator are warm.
- Run the engine at 2000 RPM for 2 minutes.
- Turn off engine and allow it to cool off.
- Install the front noise insulation.
- Check the coolant level.
• Coolant level must be at "MAX" marking with engine cold.
• Coolant level may be above "MAX" marking with engine at operating temperature.