Procedures
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Cooling System Charge Unit (VAS 6096) with (VAS 6096/1)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Refractometer (T10007)
• Engine Bung Set (VAS 6122)
• Protective eyewear
• Protective gloves
Draining
• Collect escaping coolant in a clean container for disposal or reuse.
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• To reduce pressure, cover coolant reservoir cap with cloth and carefully open.
- Open coolant reservoir cap.
- Remove the noise insulation - 1 -.
- Loosen the hose clamp - 2 -, lift the retaining clamp - 1 - and remove the air guide hose.
• Seal the connection on the charge air cooler with clean plugs from the (VAS 6122) to prevent coolant from getting in.
- Place (VAS 6208) under engine.
- Open the clamp, drain the coolant and then remove the lower coolant hose - arrow - from the radiator.
Vehicles with an EGR Cooler Pump (V400)
- Loosen the hose clamp - arrow -, drain the coolant and remove the lower coolant hose for the EGR Cooler Pump.
All Vehicles
- Remove the engine cover - arrows -.
- Remove the air filter housing.
- Loosen the hose clamp - arrow -, drain any remaining coolant and remove the additional coolant hose from the engine oil cooler.
Filling
• The cooling system is filled year year-round with a mixture of water and coolant additive. Mixture ratio.
• Only use coolant according to the electronic parts catalog ETKA. 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. They also raise the boiling point. 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 (-77 °F) (in arctic climatic countries down to approximately -35 °C (-95 °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%.
• When stronger freeze protection is needed due to the climate, the portion of coolant additive can be increased up to 60% (freeze protection down to approximately -40 °C (-104 °F)). Otherwise the freeze protection and cooling effect are reduced.
• Only use clean drinking water for mixing coolant.
• If radiator, heat exchanger, cylinder head or head seal or cylinder block were replaced, do not reuse used coolant.
• Dirty coolant may not be used again.
• Use the (T10007) to check the freeze protection in the cooling system.
Coolant Mixture Ratio
• Coolant additive (40%) and water (60%) for freeze protection down to -25 °C (-77 °F) (-77 °F)
• Coolant additive (50%) and water (50%) for freeze protection down to -35 °C (-95 °F)
• Coolant additive (60%) and water (40%) for freeze protection down to -40 °C (-104 °F)
• For the correct coolant additive, refer to the electronic parts catalog ETKA.
- Attach the coolant hose to the bottom of the radiator => [ Connect the Coolant Hose with
the Connector Coupling ] Radiator and Coolant Fan Assembly Overview.
Vehicles with an EGR Cooler Pump (V400)
- Attach the lower coolant hose to the EGR cooler pump - arrow -.
Continuation for all Vehicles
- Connect the upper coolant hose to the oil cooler - arrow -.
- Fill the coolant reservoir on (VAS 6096) with at least 8 liters of premixed coolant with the proper mixture ratio:
- Attach adapter (V.A.G 1274/8) to coolant reservoir.
- Install (VAS 6096) on (V.A.G 1274/8).
- 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.
• 6 to 10 bar positive 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 coolant reservoir.
- Fill coolant up to max marking.
- Install air filter housing.
- Install the air guides.
- Install the air guide hose with the connector coupling => [ Install the Air Guide Hoses
with the Coupling ] Charge Air Cooler Assembly Overview.
- Install the noise insulation.
- If the vehicle has an auxiliary heater, switch it on for about 30 seconds.
- Set the temperature at HI.
- Switch the A/C compressor off by pressing the ECON button.
- Start the engine and run it at approximately 1500 RPM for a maximum of 2 minutes.
- With engine running, fill coolant up to overflow hole on coolant expansion tank.
- Close the cap on the coolant reservoir.
- Run the engine at idle until both large coolant hoses on the radiator are warm.
- Turn off engine and allow it to cool off.
- Check coolant level.
• The coolant level must be between the min and max markings when the engine is cold.
• The coolant level may be at the max marking when the engine is warm.
- Add more coolant if necessary.