Cooling System, Draining and Filling
NOTE:^ To avoid frost and corrosion damage, and to increase the boiling point of the coolant, the cooling system must be filled year-round with a mixture of antifreeze/anti-corrosion concentrate and water.
^ Vehicles produced up to 06.96 have used the coolant additive G 11 ABC (color: green).
^ For vehicles produced from 07.96, only the coolant additive G 12-A8D TL 774D is used (color: red).
^ G 12 permits a lifetime fill (coolant that uses G 12 must also be replaced if it has been contaminated by oil or other foreign substances, e.g. damaged cylinder head gasket).
^ Recommended mixing ratio: 50:50
^ Cooling system capacity: approx. 9.0 liters (9.5 quarts)
^ Coolant recognition
G11: Green
G12: Red
Mixed G11 and G12: Brown
- Replace mixed coolant immediately
CAUTION: Coolant additives G11 and G12 cannot be mixed. Mixing them leads to severe engine damage.
WARNING:
^ The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth, and open carefully to relieve system pressure slowly.
^ Carefully open cap of expansion tank (to release pressure), then close it again.
Draining
1. Remove noise insulation panel.
2. Remove left air grille in bumper.
3. Place drain pan tool No. VW 1306, or equivalent, below vehicle.
4. Attach drain hose, approx. 12 mm (1/2 in.) inside diameter to drain fitting at bottom left of radiator.
5. Route other end of drain hose into drain pan.
Note: Always drain coolant into a clean container.
6. Open coolant drain plug through air intake grille opening in left side of bumper.
7. Open drain plug at left of engine below knock sensor.
8. Open drain plug on oil cooler housing behind oil filter.
9. At radiator, disconnect return line to expansion tank.
10. Hold pipe connection at radiator closed with finger.
11. Blow compressed air into detached return line until coolant no longer flows out of any of three drain openings.
Filling And Bleeding
1. Close drain plugs located at left of engine block, at oil cooler housing and at bottom left of radiator.
2. Re-connect return line at radiator.
3. Remove cap on expansion tank, attach adapter tool No. VAG 1274/1, or equivalent, and extend to 100 mm using 42 mm diameter (1-5/8 in.) hose.
4. Open vent screws at feed and return lines of heating system.
5. Add coolant until it flows from vent valves.
6. Close vent valves.
7. Re-install cover of expansion tank.
8. Disconnect 2-pin harness connector from pump unit.
9. Set heating/air conditioning controls to "LO."
10. Start and run engine at approx. 2000 RPM, for approx. 3 minutes.
11. Check fluid level in expansion tank and refill if necessary to max. level.
12. Re-connect 2-pin harness connector to pump.
13. Set heating/air conditioning controls to "HI" and blower speed to lowest setting.
14. Start and run engine at 2000-3000 RPM for about 10 minutes.
15. Stop engine (switch ignition off).
16. Switch ignition back on.
NOTE:
^ When the heating and air conditioning controls are set to "HI, " the electric pump to the heater must not make any noise.
^ Noise indicates that air is trapped in the heating system and requires the bleeding/venting process to be repeated.
17. If there are no unusual noises:
- Switch ignition off.
- Check expansion tank fluid level and refill if necessary.