Special tools and equipment: Filling

NOTE:

Cooling system is filled all year round with a mixture of water and coolant additive (combined anti-freeze and corrosion protection agent).
Use only G12+ according to TL VW 774 F as coolant additive. Other coolant additives could considerably impair anti-corrosion action in particular. Resulting damage could lead to loss of coolant and consequently to serious engine damage.
G12+ (and coolant additives marked "meeting specification TL VW 774 F(" prevent frost and corrosion damage, stop scaling and at the same time raise boiling point of coolant. For these reasons cooling system must be filled all year round with correct anti-freeze and anti-corrosion additive.
Because of its high boiling point, coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
Protection against frost must be assured down to about -25° C (or about -35° C in countries with arctic climate).
Coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. Anti-freeze ratio must be at least 40%.
If greater antifreeze protection is required in very cold climates, concentration of G12+ can be increased, but only up to 60 % (this gives antifreeze protection to about -40° C), as otherwise degree of protection is reduced again and cooling effectiveness is also impaired.
Only use clean tap water for mixing coolant.
If radiator, heat exchanger, cylinder head, cylinder head gasket or cylinder block have been replaced, do not reuse old coolant.
Coolant must not be used again if it is dirty.
Special tool T10007 must be used for testing anti-freeze concentration if cooling system contains coolant additive G12+.

Re-install drain plugs (arrows) with new seals.

Fig 1: Locating Coolant Drain Screws In Engine

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Torque Specifications: Engine Coolant Drain Plugs

Component		Nm
Drain plug on	oil filter bracket	10
	drain pipe	18

Connect coolant hose -2-.
NOTE: Disregard -item 1-.

Fig 2: Connecting Coolant Hose

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Turn drain plug (arrow) on radiator clockwise.

Fig 3: Locating Drain Plug On Radiator

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Fill replacement reservoir for cooling system charge unit VAS 6096/1 with at least 12 liters of pre-mixed coolant in mixture ratio recommended:
- G 12+ (40%) and water (60%) for frost protection to -25 ° C
- G 12+ (50%) and water (50%) for frost protection to -35 ° C
- G 12+ (60%) and water (40%) for frost protection to -40 ° C
Screw adapter V.A.G 1274/8 onto coolant expansion tank.
Install cooling system charge unit VAS 6096 onto adapter V.A.G 1274/8.
Place end of vent hose -1- in a small container -2-.
- A small amount of coolant will come out together with vented air; this drains into container.

Fig 4: Installing Cooling System Charge Unit VAS 6096 Onto Adapter V.A.G 1274/8

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Close both valves -A- and -B- (levers at right angles to direction of flow).
Connect hose -3- to compressed air line.
- Pressure: 6 to 10 bar
Open valve -B- (lever pointing in direction of flow). See Fig 5.
- Suction jet pump generates a partial vacuum in cooling system.
- Needle of indicator gauge should move into green zone.
Briefly open valve -A- as well (lever pointing in direction of flow), so that hose from coolant reservoir VAS 6096/1 fills with coolant.
Close valve -A-.
Leave valve -B- open for another 2 minutes.

Fig 5: Opening Valve (Lever Pointing In Direction Of Flow)
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- Suction jet pump will continue to build up a vacuum in cooling system.
- Gauge needle should remain in green zone.
Close valve -B-.
- If gauge needle stays in green zone, this means partial vacuum in cooling system is sufficient to draw in coolant and fill system.
- If needle has not reached green area, repeat procedure.
- If vacuum level drops, there is a leak in cooling system.
Detach hose for compressed air.
Open valve -A-. See Fig 5.
- Vacuum in cooling system causes coolant to be drawn out of replacement reservoir VAS 6096/1; cooling system is filled
Remove rubber seal from plenum chamber in direction of (arrow). See Fig 6.
Remove plenum chamber cover -1- from front.

Fig 6: Removing Rubber Seal From Plenum Chamber

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Unscrew bleeder screw in front coolant pipe at lock carrier.

Fig 7: Removing Bleeder Screw In Front Coolant Pipe At Lock Carrier
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Fill up coolant until it escapes from the coolant hose bleeder hole without bubbles.
Screw in bleeder screw with new seal (8 Nm).
Loosen spring clamp and pull back coolant hose to heater core sufficiently so that the bleeder hole (arrow) is no longer sealed by the connection.

Fig 8: Locating Bleeder Hole In Coolant Hose To Heater Core
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Fill up coolant until it escapes from the coolant hose bleeder hole without bubbles.
Slide coolant hose onto connection sleeve and install spring-type clamp.
Install coolant expansion tank cap.
Set temperature in passenger compartment to "HI".
Start engine and run at idling speed until warm.
- It should be possible to feel warm air as soon as needle of coolant temperature gauge starts to move.
Stop engine.
Check coolant level.
- Coolant level can be above MAX marking when engine is warm.
Fig 9: Identifying Coolant Level MAX/MIN
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Install front bumper:
See FRONT BUMPER (AUDI RS6) .