Radiator Versions

Vehicles with Version 1 Radiator:

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-- Attach the left coolant hose with the coupling -arrow- to the bottom of the radiator. Refer to Figure.

-- Attach the right coolant hose with the coupling -arrow- to the bottom of the charge air cooling circuit cooler. Refer to Figure.

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Vehicles with Version 2 Radiator:

-- Connect the coolant hose and the upper right coupling -1- to the radiator. Refer to Figure.

-- Attach the right coolant hose with the coupling -2- to the bottom of the charge air cooling circuit cooler. Refer to Figure.

Vehicles with Version 3 Radiator:

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-- Attach the left coolant hose with the coupling -arrow- to the bottom of the radiator. Refer to Figure.

-- Attach the coolant hoses with the coupling -1 and 2- to the charge air cooling circuit cooler. Refer to Figure.

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Continuation for All Vehicles:

-- Attach the coolant hose with a hose clamp -arrow- to the bottom of the Heater Support Pump -V488-.

Coolant, Filling without Cooling System Charge Kit - Electric Vacuum Pump :VAS 6096/2 

TIP:

Coolant, Filling with Cooling System Charge Kit - Electric Vacuum Pump :VAS 6096/2  . Refer to COOLANT, FILLING WITH Cooling System Charge Kit - Electric Vacuum Pump .

• Ignition switched off.
• To make the filling procedure easier, position the coolant reservoir as high up as possible, for example on a workshop cart or the engine and gearbox jack.

-- Fill the coolant reservoir on the Cooling System Charge Kit :VAS 6096  with at least eight liters of premixed coolant with the proper mixture ratio.

-- Install the Cooling System Tester - Adapter :V.A.G 1274/8  on the coolant expansion tank -1-.

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

-- Place the drain hose -2- in a small container -3-.

TIP:

A small amount of coolant which should be collected is drawn off with the discharged air.

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

-- Connect the hose -4- to compressed air.

• Pressure: 7 to 10 bar (101.53 to 145.04 psi) positive pressure.

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

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• The suction jet pump generates vacuum in the coolant system; indicator on display instrument must move into green area.

-- Briefly open the valve -A- by turning the lever in the flow direction so that the hose on the Cooling System Charge Kit :VAS 6096  coolant reservoir fills with coolant.

-- Close the valve -A- again.

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

• More pressure is generated in the coolant system by the suction jet pump; indicator on display instrument must stay in the green area.

-- Close the 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 the needle stands below the green area, repeat the procedure.
• If the pressure falls, check the coolant system for leaks.

-- Remove the pressure hose.

-- Open the 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 coolant expansion tank.

-- Fill the coolant to the MAX mark.

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