Cooling System, Draining and Filling

Draining and Filling

Special tools, testers and auxiliary items required

• Refractometer (T10007)

• Drip tray for VAS 6100 (VAS 6208)

• hose clip pliers (VAS 6362)

• Cooling system charge unit (VAS 6096)

• Adapter (VAG 1274/8)

Draining

CAUTION!
Risk of scalding due to hot steam and hot coolant:

• When the engine is warm the cooling system is under pressure.

• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

- Open the coolant expansion tank cap.

- Remove the noise insulation.

- Disconnect the charge air hose by lifting the clamp - 1 - and loosening the hose clamp - 2 -.





- Seal off the connections on the charge air cooler with a clean cloth.

• Collect any escaping coolant in a clean container for disposal or reuse.

- Place the (VAS 6208) under the engine.

- Remove the lower coolant hose - 1 - from the radiator and let the coolant drain.





- Remove the lower coolant hose to the after run coolant pump - arrow - and let the coolant drain.





Filling

CAUTION!
Only use tap water for mixing. Well water does not have the quality necessary to ensure proper coolant function.

• Only use G 12 plus-plus in accordance with TL VW 774 G as a coolant additive.

• Coolant additives with the note "conforming to TL VW 774 G" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. 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 greater frost protection is required for climatic reasons, the amount of coolant additive can be increased, but only up to 60% (frost protection to about -40 °C), otherwise frost protection and cooling effectiveness will be reduced.

• (T10007) is recommended for determining freeze protection density.

• If the radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse the old coolant.

Recommended Mixture Ratios





• 1 The quantity of coolant can vary depending upon the vehicle equipment.

• 2 Only use clean tap water.

- Connect the lower coolant hose - 1 - to the radiator.





- Connect the lower coolant hose to the after run coolant pump - arrow -.





- Install the charge air hose and secure using the clamps - 1 and 2 -.





- Install the noise insulation.

Filling with the (VAS 6096)

- Instal the (VAG 1274/8) onto the expansion tank.

- Fill the cooling system using the (VAS 6096). Refer to --> Operating instructions for cooling system filler unit VAS 6096.

Filling without the (VAS 6096)





- Slowly add coolant to the top mark of the hatched area on the expansion tank.

- Install the expansion tank cap.

- Start engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.

- Allow engine to run until the coolant fan starts running.

CAUTION!
Hot steam may escape when opening the expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.

- Check the coolant level, and top off if necessary:





• When the engine is warm, the coolant level must be at the top mark and when the engine is cold, it must be in the middle of the hatched field.