Cooling System, Draining and Filling
Cooling system, draining and filling
Draining
WARNING: Hot steam can escape from the expansion tank when the filler cap is opened. Cover the filler cap with a cloth and unscrew it carefully.
- Unscrew filler cap on coolant expansion tank.
- Remove noise insulation panel.
- Place drip tray V.A.G 1306 under the engine.
- If bumper has been removed from vehicle, open drain tap -arrow- on bottom of radiator (left side) by turning anti-clockwise. Fit drain hose on connection if necessary.
- If bumper has not been removed from vehicle, pull out retaining clip on bottom hose going from radiator to engine (right side), and pull hose off radiator.
- Drain coolant from engine at drain screw -arrow-.
Note: Observe disposal regulations for coolant.
Filling
Notes:
- Use only coolant additive G 12 -meeting specification VW 774 D. Identification: colored red.
- G 12 must not be mixed with any other coolant additives.
- If the fluid in the expansion tank is brown, this is an indication that G 12 has been mixed with another type of coolant. In this case the coolant must be changed.
- G 12 and coolant additives complying with specification VW 774 D prevent frost and corrosion damage, scaling and also raise the boiling point of the coolant. For this reason the system must be filed all year round with the correct additive for frost and corrosion protection.
- Particularly in countries with tropical climates, the higher boiling point of the coolant improves engine reliability when working under heavy load.
- The system must be protected against frost to about -25°C (in arctic climates to about -35°C).
- Use special tool T40007 to test coolant antifreeze protection.
- The coolant concentration should not be reduced by adding plain water, even in warmer seasons and in warmer countries. The concentration must be at least 40 %.
- If extra antifreeze protection is required in cold climates, the concentration of G 12 can be increased, but only up to a maximum of 60 % (frost protection to about -40° C); if this concentration is exceeded, the antifreeze protection will be reduced again and cooling effectiveness will also be reduced.
- Do not reuse the old coolant if the radiator, heat exchanger, cylinder head or cylinder head gasket have been replaced.
Recommended mixture ratios:
1) The capacity of the cooling system can vary depending on the equipment fitted to the vehicle.
- Replace O-ring on coolant drain screw and screw drain screw back into engine
Tightening torque: 20 Nm.
- Install bottom coolant hose and secure.
- Close coolant drain tap on radiator.
- Screw adapter V.A.G 1274/8 onto expansion tank and insert extension V.A.G 1274/10 into the adapter.
- Loosen coolant hose on heat exchanger and pull back hose far enough so that bleeder hole in hose -arrow- is no longer covered by the connection.
- Fill up coolant until it comes out at bleeder hole in coolant hose.
- Push coolant hose onto connection and tighten.
- Loosen bleeder screw on rear coolant pipe -arrow- below expansion tank.
- Fill up coolant until it comes out at bleeder screw.
- Screw in bleeder screw (20 Nm).
- Loosen bleeder screw on front coolant pipe -arrow- between power steering pump and left cylinder head.
- Fill up coolant until it comes out at bleeder screw.
- Screw in bleeder screw (20 Nm).
- Fill coolant up to max. mark.
- Close filler cap on expansion tank.
- Set heater controls to maximum heat setting.
- Start engine and let it idle for about 10 minutes.
- Maintain an engine speed of about 2000 RPM for about 5 minutes.
- Allow engine to run at idling speed until bottom hose on radiator becomes hot.
- Check coolant level and top up if necessary. When engine is at normal operating temperature coolant level must be on max. mark, and between min. and max. marks when engine is cold.
Note: When the engine is hot the cooling system is under pressure. Carefully open filer cap on expansion tank to release pressure before starting repair work.
WARNING: Hot steam can escape from the expansion tank when the filler cap is opened. Cover the filler cap with a cloth and unscrew it carefully.