Cooling System, Draining and Filling
Cooling system, draining and filling
Special tools and equipment
- VAG1306 drip tray
- VAG1274/10 with VAG1274/1 adapter or VAG1274/8
- T40007 refractometer
Draining
Note: Drain coolant into a clean container for recycling or reuse.
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 using a cloth, and open carefully to relieve system pressure slowly.
- Open coolant expansion tank cap.
- Remove noise insulation panel (arrows).
- Place VAG1306 drip tray underneath engine.
CAUTION! Observe disposal regulations for coolant!
- Remove retaining clip (arrow) from lower coolant hose and remove coolant hose from radiator.
Note: With bumper removed, coolant can be drained through radiator drain plug (arrow).
- Remove drain plug from coolant pump (arrow).
Filling
Note:
- The cooling system is filled year round with frost and corrosion protection additives.
- Until 6/96, G 011 A8 C coolant (green color) was used.
- From 7/96 on, only G 012 A8 D coolant (red color) is used.
CAUTION!
- Coolants G 011 A8 C and G 012 A8 D CANNOT be mixed. Mixing them will cause severe engine damage.
- Part numbers are for reference only. Always check with your Parts department for the latest information.
- If the fluid in the expansion tank is brown, G012 A8 D has been mixed with other coolant. In this case, flush cooling system and change coolant. To flush, fill cooling system with clear water and run engine for approximately 2 minutes. Flushing the system should remove most of the coolant residue.
- G 011 A8 C or G 012 A8 D and coolant additives marked with "according to TL VW 774C" or "according to TL VW 774 D", prevent frost and corrosion damage as well as calcium deposits. They also raise the boiling point. Therefore, cooling system must be filled year-round with frost and corrosion protection additives.
- A higher boiling point improves engine reliability under heavy load, particularly in countries with tropical climates.
- Frost protection additives must protect against frost to about -25°C (-13°F) and to about -35°C (-31°F) in arctic climates.
- The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The antifreeze ratio must be at least 40%.
- If for climatic reasons greater frost protection is required, the amount of G 011 A8 C or G 012 A8 D can be increased, but only up to 60% to obtain frost protection to about 40°C (-40°F). Otherwise frost protection and cooling effectiveness will be reduced.
- If the radiator, heater core, cylinder head or cylinder head gasket is replaced, completely replace the engine coolant.
For coolant G 0 12 A8 D, use T40007 refractometer to test frost protection in cooling system.
Recommended mixture ratios:
- Install lower radiator hose and secure.
- Replace O-ring and install coolant pump drain plug.
- Tightening torque: 30 Nm (22 ft. lbs.)
Vehicles with small cap
- Screw VAG1274/1 adapter onto coolant expansion tank.
- Attach VAG1274/10 special tool to VAG1274/1 adapter.
Vehicles with large cap
- Screw VAG1274/8 adapter onto coolant expansion tank.
- Attach VAG1274/10 special tool to VAG1274/1 adapter.
All models
Note: To fill without using special tools, loosen coolant expansion tank and lift approximately 100 mm (approximately 4 inch).
- Remove grommet holding clip at heater core and pull back grommet.
- Loosen coolant hose on heater core and pull back hose sufficiently so that bleeder hole (arrow) is no longer sealed by connection.
- Top up coolant until it flows out of coolant hose bleeder hole.
- Push coolant hose on connection and tighten.
- Install coolant expansion tank cap.
- Start engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.
- Allow engine to idle until the lower radiator hose is hot.
- Check coolant level and top up if necessary. When engine is at normal operating temperature, coolant level must be at maximum mark; when engine is cold, between min. and maximum marks.
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 using a cloth, and open carefully to relieve system pressure slowly.
- Switch engine off.