Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Pipe (V.A.G 1274/10)
• Drip Tray (V.A.G 1306) or Drip Tray For Workshop Crane (VAS 6208)
• Hose Clamp Pliers (V.A.G 1921)
• Cooling System Charge Unit (VAS 6096)
• Refractometer (T10007)
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Place Drip Tray (V.A.G 1306) or Drip Tray (VAS 6208) under engine.
Vehicles with coolant drain plug:
- Open coolant drain plug to coolant line at bottom of cooler.
Vehicles without coolant drain plug:
- Remove retaining clip - 1 - for the Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) - 2 -.
- Remove Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) from its supports and drain the coolant.
All:
- Open quick-release fasteners - arrows - and remove the engine cover.
- Remove coolant expansion tank - arrow -.
- Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 - and - 2 - connected.
- Remove coolant hose from oil cooler - arrow - and drain any remaining coolant.
Filling
• The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
• Use only Coolant Additive Plus (G 012 A8F A1) (short: G12+) "according to TL VW 774 F". 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 additive G12+ can be combined with additives G11 and G12.
• G12 and coolant additives with the designation "according to TL VW 774 F" reduce frost and corrosion damage as well as lime 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 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 greater frost protection is required, the amount of G12+ can be increased, but only up to 60% (frost protection to about -40 °C), otherwise frost protection and cooling effectiveness will be reduced.
• Only clean drinking water may be used for mixing coolant.
• If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant.
• Dirty coolant must not be re-used.
• For coolant G12+ , use refractometer (T10007) to test frost protection in cooling system.
• Secure all hose connections using hose clamps appropriate for the model type.
Procedure
Vehicles with coolant drain plug:
- Connect coolant drain plug to coolant line at bottom of cooler.
Vehicles without coolant drain plug:
- Install Engine Coolant Temperature Sensor (On Radiator) (G83) - 2 - with a new O-ring into the connection and secure it with a clip - 1 -.
All:
- Install the front noise insulation by locking the quick-release - 1 - and - 2 -.
- Install coolant hose to oil cooler - arrow -.
- Fill coolant reservoir of Cooling System Charge Unit (VAS 6096) with at least 10 liters of pre-mixed coolant with correct mixture ratio:
• G12+ (40%) and water (60%) for frost protection down to -25 °C.
• G12+ (50%) and water (50%) for freeze protection down to -35 °C.
• G12+ (60%) and water (40%) for frost protection down to -40 °C.
- Install Adapter (V.A.G 1274/8) on expansion tank.
- Assemble Cooling System Charge Unit (VAS 6096 ) on Adapter (V.A.G 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: 6 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.
- Open the valve briefly - A -, turn the lever in the direction flow to do this so that the coolant reservoir hose fills 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 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 region, repeat procedure.
If the vacuum decreases, cooling system is leaking.
- Disconnect pressurized air hose.
- Open valve - A -.
The vacuum in the cooling system causes coolant to be extracted from the Cooling System Filler Unit (VAS 6096); cooling system is filled.
- Remove Cooling System Charge Unit (VAS 6096 ) from coolant expansion tank.
- Connect Adapter For VAG 1274 Tester (V.A.G 1274/10 ) to Adapter (V.A.G 1274/8).
- Open vent screw - arrow - on the coolant pipe.
- Fill the coolant until it starts to comes out of the vent locations.
- Close bleeder screw.
- Pull off rubber seal of plenum chamber cover in direction of - arrow -.
- Remove plenum chamber cover - 1 -.
- Loosen coolant hose to heater core and pull back hose sufficiently so that the bleeder hole - arrow - in coolant hose is no longer sealed by the connection.
- Fill up coolant until it escapes from the coolant hose bleeder hole.
- Push coolant hose onto connection and secure it with the spring-type clamp.
- If present, switch on auxiliary heater for about 30 seconds.
- Twist cap for expansion tank closed.
- Start engine.
- Set 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!
Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Check coolant level.
• With cold engine, coolant level must be at MAX marking.
• Coolant level may be above MAX marking with engine at operating temperature.