Table of contents: 3.2 TDI engines ↓ 4.2 TDI engines ↓
Comment:
- A description of checking and adjusting the coolant level, as well as some tests of the cooling system, are given in Sections 4 and 5 Chapter 1. The coolant type is indicated in Specifications for Chapter 1. The following describes the replacement of the coolant.
- After replacing radiators/heat exchangers, cylinder heads/gaskets, or cylinder blocks, new coolant should be added. Contaminated coolant should always be replaced.
3.2 TDI engines
1. Open the expansion tank cap and remove the front sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
2. Prepare to collect leaking coolant.
3. Perform the steps described in paragraphs 7-9 and, only on 2nd generation engines, in paragraph 10 Section 4 Chapter 2.
Note: It is not necessary to disconnect the G83 sensor connector. On models from 06.2010, the connection of the right lower coolant hose to the radiator looks different (1 in illustration 15.1 Chapter 2).
4. Reconnect the disconnected coolant hoses. Use new O-rings when connecting the quick-release couplings.
5. Fill the VAS6096/1 canister with at least 12 liters of coolant (see illustration).
2.5. Cooling system bleeding diagram.
Screw the VAG1274/8 tester adapter onto the expansion tank and install the filling unit onto it. Place the ventilation hose (1) in a container (2) to collect a small amount of coolant blown out with the air. Close valves (A and B) and connect the hose (3) to a source of compressed air (compressor) with a pressure of 6-10 bar.
6. Open the valve (In illustration 2.5), - a partial vacuum will be created in the cooling system; the indicator arrow should enter the green zone (vacuum from 0.8 to 1.0). Briefly open valve (A) to fill the hose from canister VAS6096/1 with coolant, then close this valve. Leave the valve (B) open for another 2 minutes to restore the previous vacuum in the cooling system (the indicator arrow should remain in the green zone), then close this valve; the indicator should remain in the green zone. If the vacuum decreases, the cooling system is leaking.
7. Disconnect the compressor and open the valve (And in illustration 2.5), - the vacuum in the cooling system will lead to the suction of coolant from the canister and filling of the cooling system. After this, remove the VAS6096 filling unit from the tank and install the VAG1 274/8 tube VAG1274/10 on the adapter (see illustration).
2.7. Tube VAG1274/10 on the expansion tank.
Fill the coolant to the top of this tube.
8. Remove the upper engine cover (see Section 19 of Chapter 1). On CASA/CASB, SATA and CCMA engines, unscrew the bleeder plug on the rear coolant pipe (see illustration), fill with coolant until it starts to flow out of the hole without bubbles, and tighten the plug with a torque of 8 Nm.
2.8. Bleed hole plug on the rear coolant pipe (cASA/CASB, SATA and SSMA engines).
9. On engines except the 2nd generation. unscrew the bleed hole plug on the front side of the engine (see illustrations 2.9a-b), fill with coolant until it starts to flow out of the hole without bubbles, and tighten the plug with a torque of 8 Nm.
2.9a. Bleed hole plug on the front side of the engine (bUG, BUN and CASA/CASB engines).
2.9b. Bleed hole plug on the front side of the engine (sATA and SSMA engines).
On 2nd generation engines, unscrew the bleeder plug on the EGR radiator (see illustration 2.9c), fill with coolant until it starts to flow out of the hole without bubbles, and tighten the plug with a torque of 8 Nm.
2.9 sec. Bleed hole plug on the EGR radiator (2nd generation engines).
10. For 3.2 TDI SCR engines produced before 05.2010, follow the steps in paragraphs 11–14. For other engines, proceed to paragraph 15.
11. Connect the diagnostic tool to the diagnostic connector and select "Vehicle self-diagnosis → 01-Engine electronics → Final control diagnosis". Remove the overlay (2 in the illustration) hood lock from the guides in the front panel (1) in the direction of the arrows (A), and then separate the trim from the sides of the bumper trim and from the radiator grille in the direction of the arrows (B).
2.11. Removing the hood lock cover.
12. Remove the lid (see illustration) and unscrew the bleed hole plug located underneath it.
2.12. Bleed hole plug.
13. Remove the bleeder plug on the fuel cooler (see illustration).
2.13. Bleed hole plug on the fuel cooler.
14. Click the "Next" button (right arrow) on the diagnostic tool until the display shows "Fuel cooling pump V166". Check this item and press the "Next" button again: the fuel cooling pump will turn on periodically. As soon as from the bleeding holes (see illustrations 2.12 and 2.13) if the coolant starts to flow out without air bubbles, tighten the plugs of these holes. If necessary, restart the pump.
15. On models with an additional heater, turn it on and turn it off after 30 seconds.
16. Close the expansion tank and start the engine.
17. On engines other than the 2nd generation, set the climate control to the "HI" position and turn off the refrigeration unit using the "ECON" button. Start the engine and let it run for 3 minutes at 2000 rpm, then at idle speed (until the two large coolant hoses on the main radiator are warmed up), and then another minute at 2000 rpm. Turn off the engine and let it cool down, then check and, if necessary, adjust the coolant level (see Section 4 of Chapter 1).
18. On 2nd generation engines, set the climate control to the "HI" position and turn off the refrigeration unit using the "ECON" button. Start the engine and let it run for 1 minute at 2000 rpm, then at idle until the radiator fans come on, and then for another 3 minutes at 2000 rpm. Turn off the engine and let it cool down, then check and, if necessary, adjust the coolant level (see Section 4 of Chapter 1).
4.2 TDI engines
19. Open the expansion tank cap and remove the front sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
20. Prepare to collect leaking coolant.
21. Unscrew the drain plug (see illustration 35.3 Chapter 2) and drain the coolant.
22. Disconnect the coolant hose (2 in illustration 35.4 Chapter 2) from the radiator. On BTR/CCFA engines, additionally disconnect the coolant hose (1) from the coolant pipe leading to the auxiliary radiator and drain the coolant.
23. On models with a 4-zone climate control system, disconnect the coolant hose from the coolant pipes on the left side member (see illustration 4.9 Chapter 2) and drain the remaining coolant.
24. Tighten the coolant drain plug and connect the coolant lines indicated above. Use new O-rings when connecting the quick-connect fittings.
25. Follow the steps described in paragraphs 5-7.
Note: For 4.2 TDI engines, at least 17 litres of coolant must be poured into the VAS6096/1 canister.
26. Connect the diagnostic tool to the diagnostic connector and select "Vehicle self-diagnosis → 01-Engine electronics → Final control diagnosis".
27. On BTR and CCFA engines, remove the hood lock cover and unscrew the bleed hole bolts (see paragraphs 11-13).
28. On a CCFC engine, remove the bolt from the bleed hole on the right EGR connection (see illustration).
2.28. Bleed hole bolt on CCFA engine.
29. On models with a bleed hole in the EGR radiator, remove the bolt from it (see illustration) and fill the coolant so that it comes out of the bleed hole without air bubbles.
2.29. Bleed hole bolt on the EGR radiator.
Tighten the bleed hole bolt.
30. Click the "Next" button (right arrow) on the diagnostic tool until the display shows "Fuel cooling pump V166". Check this item and press the "Next" button again: the fuel cooling pump will turn on periodically. As soon as from the bleeding holes (see illustrations 2.12, 2.13 and 2.28) if the coolant starts to flow out without air bubbles, tighten the plugs of these holes. If necessary, restart the pump.
31. Follow the steps described in paragraphs 15-17.
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