Cooling System, Draining And Filling
Special tools and workshop equipment required
- Adapter V.A.G 1274/8
- Drip Tray VAS 6208
- Hose Clip Pliers V.A.G 1921
- Cooling System Charge Unit VAS 6096
- Refractometer T10007
Draining
Drained coolant must be stored in a clean container for disposal or reuse.
Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.
-- Open cap of coolant expansion tank.
-- Remove center noise insulation fasteners -1 through 4-.
-- Remove noise insulation frame -arrow-.
-- Place the VAS 6208 under engine.
-- Drain the coolant, by pulling off the lower coolant hose -arrows-.
Filling
The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water.
Only use one of the frost and corrosion additives approved for this vehicle. 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.
Frost and corrosion protection additives prevent freezing and corrosion damage and scaling. 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 down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -35 °C (-31 °F)).
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 increased freeze protection is needed because of the climate, the amount of G12+ can be increased, but only up to 60% (freeze protection to about -40 °C (-40 °F). Otherwise the freeze 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.
Dirty coolant may not be used again.
Secure all hose connections with hose clamps appropriate for the model.
Use the T10007 to determine the level of freeze protection in the coolant system.
-- Push the lower coolant hose onto the radiator -arrow-.
-- Fill coolant reservoir of the VAS 6096 with at least 8 liters of pre-mixed coolant with correct mixture ratio:
- Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection up to -25 °C (-13 °F).
- Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection up to -35 °C (-31 °F).
- For coolant freeze and corrosion protection additive.
-- Install the V.A.G 1274/8 on expansion tank.
-- Assemble the VAS 6096 on 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- (lever perpendicular to direction of flow).
-- Connect hose -3- to pressurized air.
- Pressure: 6 to 10 bar positive pressure.
-- Open valve -B- (lever in direction of flow).
A 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- (lever in direction of flow), so that the hose of the VAS 6096 is filled with coolant.
-- Close valve -A- again.
-- Let valve -B- remain open another 2 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 region, repeat procedure.
If the vacuum decreases, cooling system is leaking.
-- Disconnect pressurized air hose.
-- Open valve -A-.
The vacuum in the cooling system causes coolant to be extracted from the VAS 6096; cooling system is filled.
-- Check coolant level and add coolant up to max-marking.
-- Start engine, allow it to run at approximately 1500 RPM for a max. of 2 minutes and fill coolant up to overflow hole of expansion tank.
-- Close expansion tank.
-- Allow engine to run until fan turns on.
Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.
-- Check coolant level and fill if necessary. With engine at operating temperature, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.
-- Shut off engine.