2. Remove the soundproofing coating.
3. Place a catch basin from a mobile garage crane (VAS 6208) under the cooling system radiator.
Models with radiator version 1
4. Loosen the retaining clamp (arrow) and disconnect the lower left water hose from the radiator, as shown in the figure below. Drain the coolant into the coolant collection lamp.
5. Loosen the fastening clamp (arrow), disconnect the lower right water hose from the radiator, as shown in the figure below. Drain the coolant into the coolant collection lamp.
Models with radiator version 2
6. Loosen the mounting clamp (1), disconnect the lower right water hose from the radiator, as shown in the figure below. Drain the coolant into a pre-prepared collection tank.
7. Loosen the fastening clamp (1), disconnect the lower left water hose from the radiator, as shown in the figure below. Drain the coolant into a pre-prepared collection tank.
Models with radiator version 3
8. Loosen the fastening clamp (arrow), disconnect the lower left water hose from the radiator, as shown in the figure below. Drain the coolant into a pre-prepared collection tank.
9. Loosen the mounting clamps (1) and (2), then disconnect the water hoses from the intercooler radiator as shown in the figure below. Drain the coolant into a pre-prepared collection tank.
Continued for all models
10. Loosen the fastening clamp (arrow) shown in the figure below, then disconnect the lower water hose connected to the coolant recirculation pump. Drain the coolant into a pre-prepared collection tank.
Filling the system
Models with radiator version 1
1. Connect the lower left water hose to the radiator (arrow) as shown in the figure below.
2. Connect the lower right water hose (arrow) to the charge air cooler radiator as shown in the figure below.
Models with radiator version 2
3. Connect the lower right water hose (1) to the radiator of the cooling system as shown in the figure below.
4. Connect the lower right water hose (2) to the intercooler radiator as shown in the figure below.
Models with radiator version 3
5. Connect the lower left water hose (arrow) to the radiator as shown in the figure below.
6. Connect the water hoses (1) and (2) to the intercooler radiator as shown in the figure below.
Continued for all models
7. Connect the water hose and tighten the clamp to the coolant recirculation water pump (arrow) as shown in the figure below.
8. Fill the reservoir of the special coolant filling device (VAS 6096), shown in the figure below, with coolant. Volume 8 l.
9. Screw the adapter of the special test equipment (VAG1274/8) onto the expansion tank, as shown in the figure below.
10. Connect the special equipment for filling coolant (VAS6096) to the adapter (VAG1274/8), as shown in the figure below.
11. Place the air hose (1) into a small container (2) as shown in the figure below.
12. Close valves (A) and (B) by turning the levers in the required direction.
13. Connect the hose (3) to a compressed air compressor. It is necessary to create a pressure of 0.6 - 1.0 MPa (6 - 10 bar).
14. Open the valve (B) by turning it in the required direction. The vacuum is created in the cooling system by the suction pump. The pointer on the display should be in the green zone.
15. In addition, it is necessary to briefly open the valve (A) by turning the valve lever in the required direction so that the expansion tank hose (VAS6096) is filled with coolant.
16. Close the valve (A) again as shown in the figure below.
17. Leave valve (B) open for 2 minutes. The vacuum pump creates a vacuum in the cooling system. The sign must be in the green zone.
18. Close the valve (B). The indicator should remain unchanged - in the green zone.
Note:
- If the pointer is below the green zone, the process must be repeated.
- If the vacuum drops constantly, the cooling system should be checked for leaks.
19. Disconnect the pneumatic hose.
20. Open valve (A). The vacuum pump will pump coolant from the expansion tank (VAS6096) into the cooling system.
21. Remove the cooling system filling tool (VAS6096) from the expansion tank.
22. Add coolant to the expansion tank of the cooling system up to the "max" mark.
23. Install sound insulator.
For models with additional independent heating
24. Turn on the additional heater for 30 seconds.
Continued for all models
25. Set the temperature controller to the maximum temperature - pointer to "HI".
26. Turn on the air conditioning system. Press the "AC" button.
27. Start the engine and let it run for no more than two minutes at 1500 rpm.
28. With the engine running, add coolant up to the drain hole on the expansion tank.
29. Install and tighten the expansion tank cap until it clicks into place.
30. Leave the engine idling until both radiator water hoses become hot.
31. Turn off the engine and let it cool.
32. Check the coolant level in the expansion tank.
- When the engine is cold, the coolant level should be between the "min" and "max" marks.
- With the engine warmed up to normal operating temperature, the coolant level should be at the "max" mark.
33. If necessary, add coolant to bring its level to the required level.