Coolant, Draining And Filling: Procedure

Fig 1: Identifying Drain Plug

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-- Close the drain plug -1-.

-- Connect the coolant hose and clamp -1- to the left lower coolant pipe.

Fig 2: Identifying Clamp

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-- Attach the coolant hoses and clamps -1 and 3- to the left front coolant pipes.

Fig 3: Identifying Hose Clamps

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-- Fill the coolant reservoir on the Cooling System Charge Kit VAS 6096 with twelve liters of premixed coolant with the proper mixture ratio, refer to Coolant Mixture Ratio .

Fig 4: Filling Coolant Reservoir Of Cooling System Charge Unit VAS 6096

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-- Install the Cooling System Tester - Adapter VAG 1274/8 on the coolant expansion tank.

-- Attach the Cooling System Charge Kit VAS 6096 on the adapter VAG 1274/8.

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

-- 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) pressure.

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

Fig 5: Cooling System, Draining And Filling

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• 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 the coolant expansion tank hose on the Cooling System Charge Kit VAS 6096 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.

-- Remove pressurized air hose.

-- Open valve -A-.

• Coolant is extracted from the Cooling System Charge Kit VAS 6096 coolant reservoir by pressure in the coolant system and the system is filled.

-- Remove the Cooling System Charge Kit VAS 6096 from the adapter VAG 1274/8 on coolant expansion tank.

-- Connect the pipe VAG 1274/10 to the adapter VAG 1274/8.

Fig 6: Identifying Cooling System Tester - Adapter

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

-- Remove the rear engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

NOTE:

Use a cloth to catch any leaking coolant.

Fig 7: Identifying Bleeder Screws

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-- Open the bleeder screws -1- and -2- one after the other until coolant starts to come out.

-- Close the bleeder screw.

-- Remove the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Disconnect the heat exchanger coolant hose and pull it back until coolant starts to drain out of the bleed hole -arrow- in the coolant hose.

Fig 8: Identifying Bleed Hole

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-- Slide the coolant hose onto the connection and secure with a clamp.

-- If the vehicle has a parking heater, switch it on for about 30 seconds.

-- Close the cap -arrow- on the coolant reservoir until it locks.

Fig 9: Identifying Coolant Reservoir Cap

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-- Start the engine.

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

-- Press the AC  button to turn off the A/C compressor.

• The LED in the button must not 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 the engine at 2000 RPM for 2 minutes.

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

-- Install the noise insulations, refer to NOISE INSULATION, REMOVING AND INSTALLING .