Cooling System, Draining and Filling
Cooling system, draining and filling
Special tools and equipment
^ Adapter V.A.G 1274/8
^ Drip tray V.A.G 1306
^ Cooling system charge unit VAS 6096 with VAS 6096/1
^ Refractometer T1 0007
Draining
Note: Catch drained-off coolant in a clean container for re-use or disposal.
WARNING: Steam or hot coolant can escape when opening coolant expansion tank cap. Cover cap with a cloth, and open carefully.
- Open cap on coolant expansion tank.
- Remove both front wheels.
- Loosen mounting parts -1- to -4- and remove noise insulation.
- Remove front bumper
- Remove air cowl -1- in front of left charge air cooler.
- Place drip tray VAG 1306 below engine.
- Turn drain screw (arrow) on radiator counter-clockwise, if necessary install drain hose to connection.
- Disconnect coolant hose -2- and drain the coolant.
Note: Disregard -item 1-.
- Open drain screws (arrows) and drain remaining coolant at engine.
Filling
Note:
^ Cooling system is filled all year round with a mixture of water and coolant additive (combined anti-freeze and corrosion protection agent).
^ Use only G12+ according to TL VW 774 F as coolant additive. Other coolant additives could considerably impair anti-corrosion action in particular. Resulting damage could lead to loss of coolant and consequently to serious engine damage.
^ G12+ (and coolant additives marked "meeting specification TL VW 774 F') prevent frost and corrosion damage, stop scaling and at the same time raise boiling point of coolant. For these reasons cooling system must be filled all year round with correct anti-freeze and anticorrosion additive.
^ Because of its high boiling point, coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
^ Protection against frost must be assured down to about -25° (or about -35°C in countries with arctic climate).
^ Coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. Anti-freeze ratio must be at least 40%.
^ If greater antifreeze protection is required in very cold climates, concentration of G12+ can be increased, but only up to 60 % (this gives antifreeze protection to about -40°C), as otherwise degree of protection is reduced again and cooling effectiveness is also impaired.
^ Only use clean tap water for mixing coolant.
^ If radiator, heat exchanger, cylinder head, cylinder head gasket or cylinder block have been replaced, do not reuse old coolant.
^ Coolant must not be used again if it is dirty.
^ Special tool T10007 must be used for testing anti-freeze concentration if cooling system contains coolant additive G12+.
- Re-install drain plugs (arrows) with new seals.
Drain plug on
Oil filter bracket 10 Nm
Drain pipe 18 Nm
- Connect coolant hose -2-.
Note: Disregard -item 1-.
- Turn drain plug (arrow) on radiator clockwise.
- Fill replacement reservoir for cooling system charge unit VAS 6096/1 with at least 12 liters of pre-mixed coolant in mixture ratio recommended:
^ 12+ (40%) and water (60%) for frost protection to -25°C
^ 12+ (50%) and water (50%) for frost protection to -35°C
^ 12+ (60%) and water (40%) for frost protection to -40°C
- Screw adapter V.A.G 1274/8 onto coolant expansion tank.
- Install cooling system charge unit VAS 6096 onto adapter V.A.G 1274/8.
- Place end of vent hose -1- in a small container -2-.
^ A small amount of coolant will come out together with vented air-, this drains into container.
- Close both valves -A- and -B- (levers at right angles to direction of flow).
- Connect hose -3- to compressed air line.
^ Pressure: 6 to 10 bar
- Open valve -B- (lever pointing in direction of flow).
^ Suction jet pump generates a partial vacuum in cooling system.
^ Needle of indicator gauge should move into green zone.
- Briefly open valve -A- as well (lever pointing in direction of flow), so that hose from coolant reservoir VAS 6096/1 fills with coolant.
- Close valve -A-.
- Leave valve -B- open for another 2 minutes.
^ Suction jet pump will continue to build up a vacuum in cooling system.
^ Gauge needle should remain in green zone.
- Close valve -B-.
^ If gauge needle stays in green zone, this means partial vacuum in cooling system is sufficient to draw in coolant and fill system.
^ If needle has not reached green area, repeat procedure.
^ If vacuum level drops, there is a leak in cooling system.
- Detach hose for compressed air.
- Open valve -A-.
^ Vacuum in cooling system causes coolant to be drawn out of replacement reservoir VAS 6096/1 - cooling system is filled
- Remove rubber seal from plenum chamber in direction of (arrow).
- Remove plenum chamber cover -1-from front.
- Unscrew bleeder screw in front coolant pipe at lock carrier.
- Fill up coolant until it escapes from the coolant hose bleeder hole without bubbles.
- Screw in bleeder screw with new seal (8 Nm).
- Loosen spring clamp and pull back coolant hose to heater core sufficiently so that the bleeder hole (arrow) is no longer sealed by the connection.
- Fill up coolant until it escapes from the coolant hose bleeder hole without bubbles.
- Slide coolant hose onto connection sleeve and install spring-type clamp.
- Install coolant expansion tank cap.
- Set temperature in passenger compartment to "HI".
- Start engine and run at idling speed until warm.
^ It should be possible to feel warm air as soon as needle of coolant temperature gauge starts to move.
- Stop engine.
- Check coolant level. 0 Coolant level can be above MAX marking when engine is warm.
- Install front bumper: