Cooling System, Filling

Special tools and workshop equipment required 

• Cooling System Tester - Adapter:V.A.G 1274/8 
• Cooling System Charge Kit:VAS 6096 

-- Make sure that all coolant hoses are connected.

For Vehicles with a Gasoline Engine

-- Perform the "Cooling system, filling and bleeding" function using the Vehicle Diagnostic Tester. Refer to Diagnostic Entries .

Continuation for All Vehicles

-- Fill the coolant reservoir on the cooling system charge unit -1- with 10 liters of premixed coolant with the proper mixture ratio.

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-- Install the Cooling System Tester - Adapter:V.A.G 1274/8  -3- on the coolant expansion tank -2-.

-- Connect the Cooling System Charge Kit:VAS 6096  -4- to the adapter -3-.

-- Guide the drain hose -5- into the container -6-.

Requirement

• The discharged air will carry along a small amount of coolant which must be collected.

-- Close the valves -A and B- by turning lever at a right angle to the flow direction.

-- Connect a commercially available pressure hose -7-.

Requirement

• The pressure must be between 6 and 10 bar (87.02 and 145.04 psi).

-- Open the valve -B- by turning the lever in the flow direction.

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-- Additionally, open the valve -A-, until the cooling system charge kit hose is filled with coolant.

-- Close the valve -A-.

-- Leave the valve -B- open for two minutes.

Requirement

• A further vacuum is created in the cooling system by the suction jet pump. The indicator of the display -1- must move into the green range and remain there.

-- Close the valve -B-.

Requirement

• Repeat the procedure if the needle remains below the green range.
• Check the coolant system for leaks if the vacuum decreases.

-- Remove the commercially available pressure hose.

-- Open the valve -A-, until the cooling system is filled and there is no vacuum anymore.

Tip

Coolant is extracted from the cooling system charge unit coolant reservoir by pressure in the coolant system and the system is filled.

-- Remove the cooling system charge unit from the coolant reservoir.

-- Fill the coolant.

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Requirement

• The coolant level must be approximately 5 mm above the MAX marking or right at the MAX marking.

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Screw on the coolant expansion tank cap until it locks.

Vehicles with Diesel Engine

-- Perform the "Cooling system, filling and bleeding" function using the Vehicle Diagnostic Tester. Refer to Diagnostic Entries .

Continuation for All Vehicles

-- Refer to Cooling System, Checking Coolant Concentration  .