Coolant Mixture Ratio

Coolant additive (40%) and water (60%) for freeze protection down to -25°C (-13 °F)

Coolant additive (50%) and water (50%) for freeze protection down to -35°C (-31 °F)

Coolant additive (60%) and water (40%) for freeze protection down to -40 °C (-40 °F)

Coolant additive

-- Connect the coolant hose -arrow- and connector coupling to the right coolant pipe. Refer to Figure.

Fig 1: Identifying Coolant Hose -Arrow- And Connector Coupling To Right Coolant Pipe

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-- Connect coolant hoses to coolant pipes for the heater heat exchanger -arrows-.

Fig 2: Identifying Hose Connections To Heater Core

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Vehicles Built through 05.10:

-- Connect the coolant hose -1- and the lower right release coupling to the radiator. Refer to Figure.

Fig 3: Identifying Engine Coolant Temperature (ECT) Sensor On Radiator Outlet -G83- -2-

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Vehicles Built from 06.10:

-- Connect the coolant hose -1- and the lower right release coupling to the radiator. Refer to Figure.

Fig 4: Identifying Retaining Clip -2-, Connector -3-, And Engine Coolant Temperature (ECT) Sensor

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All Vehicles:

-- Connect the coolant hose -arrow- to the left coolant pipe.

Fig 5: Identifying Coolant Hose -Arrow- To Left Coolant Pipe

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-- Fill coolant reservoir on the VAS 6096 with at least 12 liters of premixed coolant with the proper mixture ratio:

Fig 6: Filling Coolant Reservoir Of Cooling System Charge Unit VAS 6096 With At Least 15 Liters Of Pre-Mixed Coolant

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-- Attach the V.A.G 1274/8 to coolant reservoir.

-- Install the VAS 6096 on the V.A.G 1274/8.

-- Place air outlet -1- in a small container -2-.

NOTE:

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.

Pressure: 6 to 10 bar pressure.

-- Open valve -B- by turning level in direction of flow.

Fig 7: Identifying Cooling System, Draining And Filling

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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 the 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.

NOTE:

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 form the V.A.G 1274/8 on coolant reservoir.

-- Connect the V.A.G 1274/10 to the V.A.G 1274/8.

Fig 8: Identifying V.A.G 1274/10 Connected To V.A.G 1274/8

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-- Fill with coolant until the coolant system tester tube is full. Fill again during the bleeding procedure if necessary.

-- Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Fig 9: Identifying Engine Cover -Arrows-

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-- Open the vent plug -arrow- on the top of the left coolant pipe until the coolant is allow to come out until there are no bubbles.

Fig 10: Identifying Vent Plug -Arrow- On Top Of Left Coolant Pipe

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-- Close the bleeder screw.

-- Open the front vent plug -arrow- on the engine and let the coolant drain out until there are no bubbles.

Fig 11: Identifying Front Vent Plug -Arrow- On Engine

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-- Close the bleeder screw.

Vehicles Built through 05.10:

-- Connect the vehicle diagnosis tester, turn on the ignition and select OBD .

-- Select the following menu points in vehicle on board diagnostic:

"01- Engine electronics"
"Output Diagnostic Test Mode"

-- Remove the cover -2- from the guide in the lock carrier -1- -arrows A-.

Fig 12: Identifying Removal Of Cover -2- From Guide In Lock Carrier -1- -A Arrows-

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-- Remove the side cover on the bumper and radiator grille -arrows B-.

-- Remove the cover -arrow- and open the vent plug underneath.

Fig 13: Identifying Cover -Arrow- And Open Vent Plug Underneath

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-- Open the bleeder screw -arrow- on the fuel cooler.

Fig 14: Identifying Bleeder Screw -Arrow- On Fuel Cooler

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-- Press the → button until the following display appears:

Fig 15: Identifying Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-)

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Fuel cooler pump -V166-

-- To activate, press the → button.

The fuel cooler pump is controlled in intervals.

-- Close the vent plug as soon as coolant comes out without any bubbles; repeat "output diagnostic test mode" if necessary.

All Vehicles:

-- If the vehicle has an auxiliary heater, switch it on for about 30 seconds.

-- Close coolant reservoir cap.

-- Start the engine.

-- Set the temperature to "HI" for all zones and set the fan speed as low as possible (0).

-- Press the ECON/ON/OFF button to turn off the A/C compressor.

The LED inside the button must come on.

-- 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 engine at 2000 RPM for 1 minute.

-- Turn off engine and allow it to cool off.

-- Install the noise insulation. Refer to the appropriate service information .