Cooling System, Draining and Filling
Cooling System, Draining and Filling
Special tools, testers and auxiliary items required
• Refractometer (T10007)
• Drip tray for VAG 1202 (V.A.G 1306/)
• Spring-type clip pliers (VAS 6362)
• Cooling system charge unit (VAS 6096)
• Adapter for cooling system tester (V.A.G 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.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce the pressure by covering the coolant reservoir cap with a rag and opening it carefully.
• Drained coolant must be stored in a clean container for disposal or reuse.
• Follow disposal regulations.
- Open coolant reservoir cap.
- Remove insulation pan.
• Collect any leaking fluid with the drip tray for VAS 6100 (VAS 6208).
- Place drip tray (VAS 6208) under engine.
- Remove coolant hose clip - arrow - downward and remove coolant hose from radiator quick-release coupling.
- In addition, to drain coolant from the engine, disconnect coolant hose at the oil cooler - arrow -.
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.
• G 12 plus-plus prevents freezing and corrosion damage and scaling and it raises 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.
• Freeze protection 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.
• If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
• The refractometer (T10007) is recommended for determining freeze protection density.
Recommended Mixture Ratios
* The quantity of coolant can vary depending upon the vehicle equipment.
* Only use clean tap water.
- Install lower coolant hose and secure with retaining clamp - arrow -.
- Install coolant hose to oil cooler - arrow -.
- Install insulation pan.
Using cooling system charge unit (VAS 6096)
- Install adapter (V.A.G 1274/8) on coolant reservoir.
- Fill coolant circuit using the cooling system charge unit (VAS 6096). Refer to --> Operating instructions for cooling system charge unit VAS 6096.
Without cooling system charge unit (VAS 6096):
- Slowly fill coolant up to the upper marking in the hatched area on the expansion tank.
- Close coolant reservoir.
- Start engine and maintain an engine speed of about 2000 rpm for approximately 3 minutes.
- Let engine run at idle until coolant fan switches on.
CAUTION!
Risk of scalding due to hot steam and hot coolant:
• When the engine is warm the cooling system is under pressure.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce the pressure by covering the coolant reservoir cap with a rag and opening it carefully.
- Check coolant level, and top off if necessary:
• When engine is warm, coolant level must be at top marking and when the engine is cold, it must be in the middle of the hatched field.