Coolant, Draining And Filling
Special tools and workshop equipment required
- Cooling System Tester - AdapterVAG1274/8
- Cooling System Tester - AdapterVAG1274/10
- Cooling System Charge KitVAS 6096
- Shop Crane - Drip TrayVAS6208
- Hose Clip PliersVAS6362
- RefractometerT10007 A
- Vehicle Diagnostic Tester
Draining
-- On vehicles with air suspension, activate vehicle lift mode. Refer to VEHICLE LIFT MODE .
Risk of scalding due to hot steam and hot coolant.
- The coolant system is under pressure when the engine is warm.
- Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.
-- Open the coolant reservoir cap.
-- Remove the front noise insulation -1-. Refer to NOISE INSULATION, REMOVING AND INSTALLING .
Collect escaping coolant in a clean container for disposal or reuse.
-- Place the Shop Crane - Drip TrayVAS6208 under engine.
-- Remove the right lower coolant hose -arrow- from the radiator by lifting the clamp and let the coolant drain out.
-- Open the clamps -1 and 2-, drain the coolant and then remove the coolant hoses from the coolant pipes.
-- Open the clamps -arrows-, drain the coolant and remove the coolant hoses from the coolant pipes on the left longitudinal member.
Ignore item -2-.
-- Open the clamp -1-, drain the coolant and remove the coolant hose from the coolant pipe on the lock carrier.
-- Remove the coolant hose from the engine oil cooler by loosening the hose clamp -arrow- and letting the coolant drain out.
Refer to COOLANT, DRAINING AND FILLING .
Tightening Specifications
- Refer to OVERVIEW - COOLANT PUMP AND THERMOSTAT
- Refer to OVERVIEW - COOLANT PIPES .
- The ignition is off.
Only mix distilled water with coolant additives. Using distilled water provides optimum corrosion protection.
The mixture of the water used greatly influences the effectiveness of the coolant. The water quality to be used is based on the contents, which can be specific to a country or even a region. Distilled water fulfills all requirements. For this reason, use distilled water when adding coolant or filling coolant for the first time.
Use only coolant additives listed. 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. Additionally, the boiling temperature will be raised. For this reason the cooling system must be filled with coolant additive year-round.
Because of its high boiling point, the coolant contributes to engine reliability under heavy engine loads, particularly in countries with tropical climates.
The RefractometerT10007A MUST be used to determine the current freeze protection value.
Protection against frost must be assured down to minimum -25 °C (-13 °F) (in arctic climatic countries down to approximately -36 °C (-32.8 °F)). The freeze protection may only be increased, when stronger freeze protection is needed due to the climate. But only down to -48 °C (-54 °F), otherwise the effectiveness of the coolant decreases.
The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The frost protection must be at least -25 °C (-13 °F).
Read the freeze protection value on the scale for the coolant additive that has been added.
The temperature on the RefractometerT10007A corresponds to the >>freezing point<<. At this temperature, ice crystals may begin to form in the coolant.
Do not reuse used coolant.
Only use water/coolant additive to lubricate the coolant hoses.
Refer to COOLANT, DRAINING AND FILLING .
- Coolant (40%) and water (60%) for freeze protection down to -25 °C (-13 °F)
- Coolant (50%) and water (50%) for freeze protection down to -36 °C (-32.8 °F)
Procedure
-- Attach the coolant hose and clamp -arrow- to the oil cooler.
-- Attach the coolant hose and clamp -1- to the coolant pipe on the lock carrier.
-- Attach the coolant hoses and clamps -arrows- to the coolant pipes on the left longitudinal member.
-- Attach the coolant hoses and clamps -1 and 2- to the coolant pipes.
-- Attach the coolant hose -arrow- with the right lower decoupling element to the radiator. Refer to Figure.
-- Fill the coolant reservoir on the Cooling System Charge KitVAS6096 with at least twelve liters of premixed coolant with the proper mixture ratio. Refer to COOLANT, DRAINING AND FILLING :
-- Install the Cooling System Tester - AdapterVAG1274/8 on the coolant expansion tank.
-- Attach the Cooling System Charge KitVAS6096 on the Cooling System Tester - AdapterVAG1274/8.
-- Place the air outlet hose -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 the hose -3- to compressed air.
- Pressure: 6 to 10 bar (87 to 145 psi) positive pressure.
-- Connect Vehicle Diagnostic Tester to the vehicle.
-- Select the following menu items on the Vehicle Diagnostic Tester.
- Guided Functions mode
- 01 - Simos Fuel Injection and Ignition
- Functions - Engine
- 01 - Coolant circuit bleeding
-- Follow the instructions given in the Vehicle Diagnostic Tester.
-- Open the valve -B- by turning level in direction of flow.
- A further vacuum is created in the cooling system by the suction jet pump. Needle on the instrument display must travel into the green region.
-- Briefly open valve -A- by turning lever in direction of flow so that hose on the Cooling System Charge KitVAS6096 coolant reservoir fills with coolant.
-- Close valve -A- again.
-- Leave valve -B- open another two 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 area, repeat procedure.
If pressure falls, check coolant system for leaks.
-- Remove pressurized air hose.
-- Open valve -A-.
- Coolant is extracted from the Cooling System Charge KitVAS6096 coolant reservoir by pressure in the coolant system and the system is filled.
-- Remove the Cooling System Charge Kit VAS6096 from the Cooling System Tester - AdapterVAG1274/8 on coolant expansion tank.
-- Connect the pipe Cooling System Tester - AdapterVAG1274/10 to the Cooling System Tester - AdapterVAG1274/8.
-- Fill the coolant until the coolant system tester tube is full. Fill again during the bleeding procedure if necessary.
-- Remove the rear engine cover -2- upward.
Use a cloth to catch any leaking coolant.
-- Open the bleeder screws -1 and 2- on the charge air coolers one after the other until coolant starts to come out.
-- Close the bleeder screw.
-- Open the bleeder screw -arrow- on the left and right coolers for the charge air cooling circuit until coolant starts to come out.
-- Close the bleeder screw.
-- If the vehicle has a parking heater, switch it on for about 30 seconds.
-- Close the coolant reservoir cap.
-- Start the engine.
-- Set the temperature to "HI" for all zones and set the fan speed (0).
-- Press the ECON/ON/OFF button to turn off the Air Conditioning (A/C) compressor.
-- Run the engine at 2000 RPM for 3 minutes.
-- Run the engine at idle until both large coolant hoses on the radiator are warm.
-- Run the engine at 2000 RPM for 1 minutes.
-- Turn off engine and allow it to cool off.
-- Install the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .
Refer to COOLANT, DRAINING AND FILLING .
- Coolant level must be at MAX-marking -arrow- with engine cold.
- Coolant level may be above MAX marking with engine at operating temperature.
-- On vehicles with air suspension, deactivate vehicle lift mode. Refer to VEHICLE LIFT MODE .