Cooling system, draining and filling: Filling

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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.
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.
Dirty coolant must not be re-used.
For coolant G12+ , use refractometer T10007 to test frost protection in cooling system.

Fig 1: Removing Drain Plug On Coolant Thermostat Housing

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Re-install drain plug - arrow - with new sealing ring.

Fig 2: Filling Reservoir VAS 6096/1 With At Least 12 Liters Of Premixed Coolant

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Fill coolant reservoir of Cooling System Charge Unit VAS 6096 with at least 12 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

Install adapter V.A.G 1274/8 onto expansion tank.
Assemble 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 - , turn lever perpendicular to direction of flow to do this.

Connect hose - 3 - to pressurized air.

Pressure: 6 to 10 bar positive pressure.

Fig 3: Opening Valve

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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 - , turn lever in direction of flow to do this, so that coolant reservoir hose of cooling system filler unit VAS 6096 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 the display instrument must remain in green region, then sufficient vacuum in cooling system is obtained for the upcoming filling.

If needle stands below the green region, repeat procedure.

If vacuum decreases, cooling system is leaking.

Disconnect pressurized air hose.
Open valve - A -.

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

Detach cooling system filler unit VAS 6096 from adapter V.A.G 1274/8 on coolant expansion tank.

Fig 4: Connecting Pipe For Cooling System Tester V.A.G 1274/10 To Adapter

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

Fig 5: Identifying Plenum Chamber Cover & Removing Rubber Seal

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Remove plenum chamber cover rubber seal.
Remove plenum chamber cover - 1 - toward front - arrows -.

Fig 6: Sliding Back Boot For Coolant Hoses At Connection Of Heater Core

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Slide back boot for coolant hoses at connection of heater core.
Loosen coolant hose to heater core and pull back hose sufficiently so that the bleeder hole - arrow - is no longer sealed by connection.
Fill up coolant until it escapes from the coolant hose bleeder hole without bubbles.
Push coolant hose on connection and tighten.

Twist cap for expansion tank closed.
Start engine.
Set 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.