Cooling System, Draining and Filling
Cooling system, draining and filling
Special tools, repair equipment, testers, measuring instruments and other items required
^ Refractometer T10007
^ Drip tray VAG 1306
^ Assembly tools for spring clips VAS 5024
Draining
Note: Catch drained-off coolant in a clean container for re-use or disposal.
WARNING: Hot steam can escape when cap on expansion tank is opened. Cover cap with cloth and open carefully.
^ Open cap on coolant expansion tank.
^ Remove noise insulation -arrows-.
^ Place drip tray VAG 1306 under engine.
^ Pull retaining clip -1- for coolant temperature sender -G2- -2- off bottom coolant hose and drain off coolant from radiator.
^ Also disconnect coolant hose from oil cooler -arrow- and drain off remaining coolant.
Note: Observe disposal regulations.
Filling
Notes:
^ Only use coolant additive G 12 meeting specification TL VW 774 D. Identifiable by: red color
CAUTION: The two coolant additives G 011 A8 C and G 012 A8 D should never be mixed as this will result in serious engine damage.
^ Never mix G 12 with other coolant additives.
^ If fluid in expansion tank is brown, G 012 A8 D has been mixed with a different type of coolant. In this case, Rush out cooling system and replace coolant. To Rush out, fill cooling system with clean water and allow engine to run for approximately 2 minutes. This should remove virtually all the old coolant.
^ G 011 A8 C or G 012 A8 D and coolant additives marked "meeting TL VW 774 C" or "meeting TL VW 774 D" prevent frost and corrosion damage and stop scale forming. They also raise the boiling point. The cooling system must therefore be filled all year round with the correct anti-freeze and anti-corrosion additive.
^ On account of the higher boiling point, the coolant helps to enhance engine reliability under heavy loads particularly in countries with tropical climates.
^ Frost protection must be guaranteed to around -25°C (in countries with arctic climate to around-35°C).
^ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40 %.
^ If greater frost protection is required in very cold climates, the amount of G 012 As D can be increased, however only up to 60 % (giving frost protection to around -40°C) as otherwise frost protection decreases again and cooling efficiency is also impaired.
^ Only use clean drinking water for mixing coolant.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:
1) Coolant capacity 7.0 liters; may vary depending upon vehicle equipment.
^ Insert coolant temperature sender -G2 -2- back into bottom coolant hose and attach clip -1-.
^ Attach coolant hose to oil cooler.
^ Screw adapter VAG1274/8 onto coolant expansion tank.
^ Fit special tool VAG 1274/10 onto adapter.
^ Fill cooling system with coolant.
^ Seal expansion tank.
^ Start engine and maintain engine speed of approximately 2000 RPM for approximately 3 minutes.
^ Then allow engine to run at idling speed until lower hose on radiator becomes hot.
WARNING: Hot steam can escape when cap on expansion tank is opened. Cover cap with cloth and open carefully.
^ 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, coolant level must be between min. and maximum marks.
^ Switch off engine.