1.2 TDI CR engine (EA189) · Cooling · Cooling system/coolant

Draining and adding coolant

⇒ 1.3.1 Draining

⇒ 1.3.2 Filling with coolant.

1.3.1 Draining

On a warm engine, the cooling system is under high pressure.

Cover filler cap on expansion tank with a cloth and open carefully to release pressure.

Open filler cap on coolant expansion tank.
Remove noise insulation ⇒ Rep. gr. 50.
Remove connecting hose »hot side« to charge air pipe ⇒ 2 Charge air system.

Place drip tray - VAS 6208- beneath engine.

Pull off coolant hoses -arrows-.

Remove lower coolant hose from radiator.

1.3.2 Filling with coolant

⇒ 1.3.3 Filling: Using cooling system charge unit VAS 6096 only

⇒ 1.3.4 Topping up

If coolant has been drained, cooling system must be filled using cooling system charge unit - VAS 6096- ⇒ 1.3.2 Filling with coolant.

Note

The water used for mixing has a major influence on the effectiveness of the coolant. Because the water quality differs from country to country and even region to region, Volkswagen has decided to define the quality of the water to be used in the coolant system. Distilled water fulfils all requirements.
Use only coolant additives which conform with the ⇒ Electronic parts catalogue (ETKA). Other coolant additives may reduce corrosion protection substantially. The resulting damage could lead to loss of coolant and subsequent severe damage to the engine.
Mixed in the proper proportions, coolant inhibits frost and corrosion damage as well as scaling. Such additives also raise the boiling point of the coolant. For this reason, the cooling system must be filled all-year-round with coolant additives.
Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
Frost protection must be guaranteed down to about -25 °C (in countries with Arctic climates, down to about -35 °C).
Do not reduce the coolant concentration by adding water even in warmer seasons and in warmer countries. The coolant additive concentration must be at least 40%.
If a stronger anti-freeze mixture is necessary due to harsher weather conditions, the coolant additive content can be increased. However, this is only permitted to 60% (antifreeze protection to about -40 °C). Otherwise, the antifreeze protection will be reduced again and the cooling effect will be impaired.
If radiator, heat exchanger, cylinder head or cylinder head gasket is renewed, do not reuse old coolant.
The refractometer - T10007A- is recommended for determining the current anti-freeze density.

Recommended mixture ratios:

Coolant additive (40 %) and distilled water (60 %) for frost protection to -25 °C
Coolant additive (50%) and distilled water (50%) for frost protection to -35°C
Coolant additive (60 %) and distilled water (40 %) for frost protection to -40 °C

1.3.3 Filling: Using cooling system charge unit - VAS 6096- only

Cooling system is leak tight

Fill coolant expansion tank of -VAS 6096- with at least 8 litres of pre-mixed coolant in correct mixture ratio:
Screw adapter for cooling system tester - V.A.G 1274/8- onto coolant expansion tank.
Attach cooling system charge unit - VAS 6096- to adapter - V.A.G 1274/8-.
Feed vent hose -1- into a small container -2-.

Close valves -A- and -B- (turn lever transverse to direction of flow to do this).
Connect hose -3- to compressed air.

Pressure: 6 to 10 bar.

Open valve -B-; turn lever in direction of flow to do this.

In cooling system, vacuum is generated by suction jet pump; needle of gauge must move into green area.

Also briefly open valve -A- (turn lever in direction of flow to do this) so that hose on -VAS 6096- coolant reservoir fills with coolant.
Close valve -A- again.
Leave valve -B- open for a further 2 minutes.

Vacuum continues to be generated in the cooling system by the suction jet pump; the needle of gauge must remain in green range.

Close valve -B-.

The needle on the gauge should stop in the green zone. The vacuum level in the cooling system is then sufficient for subsequent filling.

Pull off compressed air hose.
Open valve -A-.

Vacuum in cooling system causes coolant to be extracted from
- VAS 6096- coolant reservoir and coolant system to be filled.

Remove cooling system charge unit - VAS 6096- from coolant expansion tank.

Fill coolant up to “max.” mark.
Fit expansion tank cap.
Start the engine. Keep engine speed at approx. 2000 rpm for approx. 3 minutes.
Then run engine at idling speed until radiator fan cuts in.
Check coolant level and top up as needed. When engine is at normal operating temperature, the coolant level must be at the upper mark; when engine is cold, in the middle of the shaded field.

1.3.4 Topping up

Cooling system is leak tight

Permitted: Without cooling system charge unit - VAS 6096- :

Slowly fill coolant in up to upper marking of hatched field on expansion tank.