Cooling system, draining and filling: Filling

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Tightening torques → Coolant pump and coolant thermostat, assembly overview , → Coolant pipes, assembly overview .
Ignition switched off.

NOTE:

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.
Do not reuse contaminated coolant.
For coolant G12+, use refractometer T10007 to test frost protection in cooling system.

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Install drain plug - 1 - with new O-ring on Map Controlled Engine Cooling Thermostat F265.

NOTE:

Ignore - 2 -.

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Reinstall drain plug - arrow - with new gasket at front coolant pipe.

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Fill coolant reservoir of Cooling System Charge Unit VAS 6096 with at least 15 liters of pre-mixed coolant with correct mixture ratio:

G12+ (40%) and water (60%) for frost protection up to -25° C
G12+ (50%) and water (50%) for frost protection up to -35° C
G12+ (60%) and water (40%) for frost protection up to -40° C

Attach adapter V.A.G 1274/8 to coolant expansion tank.
Install 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.

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Open valve - B -, to do this turn lever in direction of flow.

A vacuum is created in cooling system by suction jet pump.

Needle on instrument display must travel into green region.

Also briefly open valve - A - by turning lever in direction of flow so that Cooling System Charge Unit VAS 6096 coolant reservoir hose is filled with coolant.
Close valve - A - again.
Let valve - B - remain open another 2 minutes.

A further vacuum is created in cooling system by suction jet pump.
Needle on instrument display must still remain in green region.

Close valve - B -.

Needle in display instrument must remain in green region, then sufficient vacuum in cooling system is obtained for upcoming filling.

If needle stands below green region, repeat procedure.

If vacuum decreases, cooling system is leaking.

Disconnect pressurized air hose.
Open valve - A -.

The vacuum in the cooling system has the effect of extracting coolant from coolant reservoir of VAS 6096 ; cooling system is filled.

Detach Cooling System Charge Unit VAS 6096 from adapter V.A.G 1274/8 on coolant expansion tank.

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Connect pipe for cooling system tester V.A.G 1274/10 to adapter.

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Remove rubber seal - 1 - for plenum chamber covers.
Remove plenum chamber cover - 2 -.

NOTE:

Ignore - 3 -.

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Open bleeder screws - arrows -.
Fill up coolant until it escapes from bleeder holes in coolant hoses.
Close bleeder screws.
If present, switch on auxiliary heater for about 30 seconds.

Twist cap for expansion tank closed.
Start engine.
Set left and right 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.
Check coolant level.

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Coolant level must be at "MAX" marking with engine cold.
Coolant level may be above "MAX" marking with engine at operating temperature.