Coolant, Draining and Refilling

Coolant, draining and refilling

Special tools and equipment:

^ VAG1274/8 Adapter
^ VAG1274/10 Adapter for VAG1274 Cooling system tester
^ VAG1306 Drip tray for VAG1202A
^ VAG1921 Hose clip pliers
^ T10007 Refractometer

Draining

Note: Drained coolant must be stored in a clean container for disposal or reuse.

WARNING: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

- Open cap of coolant expansion tank.





- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.





- Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
- Place VAG1306 drip tray beneath engine.

Vehicles with drain plug





- Turn radiator drain plug -2- counterclockwise. If needed, attach accessory hose to connection flange and drain coolant.

Vehicles without drain plug
- Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
- Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.

All
- In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.





Filling

Note:
^ The cooling system must be filled year round with frost and corrosion protection additives.
^ Only use coolant additive G 012 A8 D (according to TL VW 774 D). Characteristic color: red

CAUTION: G 012 A8 D and other coolant additives must not be mixed. If mixed, major engine damage will occur.

^ If the fluid in expansion tank is brown, G 012 A8 D has been mixed with other coolant. In this case, flush the cooling system and change the coolant. To flush, fill the cooling system with clear water and let the engine run for approximately 2 minutes. Flushing the system should remove most of the old coolant.
^ G 012 A8 D and coolant additives marked with according to TL VW 774 D prevent frost and corrosion damage as well as lime deposits. They also raise the boiling point. Therefore, the 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 must be ensured to about -25°C (about -35°C in countries with arctic climates).
^ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%.
^ If for climatic reasons greater frost protection is required, the amount of G 012 A8 D can be increased, but only up to 60% (frost protection to about -40°C), otherwise frost protection and cooling effectiveness will be reduced again.
^ Use only clean drinking water for mixing with the coolant.
^ If the radiator, heater core, cylinder head or cylinder head gasket is replaced, completely replace the engine coolant.
^ For coolant G 012 A8 D, use T10007 refractometer to test frost protection in cooling system.

Recommended mixture ratios:





Vehicles with drain plug





- Unscrew drain plug -2- at radiator clockwise.

Vehicles without drain plug
- Insert Engine Coolant Temperature (ECT) sensor (on radiator) -G83- with new O-ring into outlet and secure it with retaining clamps.

All





- Connect coolant hose to oil cooler (arrow).





- Screw VAG1274/8 adapter onto expansion tank.
- Attach VAG1274/10 special tool to VAG1274/1 adapter.





- Pull off rubber seal of plenum chamber cover in direction of (arrow).
- Remove cover -1- toward front.





- Remove front engine cover (arrows).





- Remove bleeder screw (arrow).
- Fill with coolant until it escapes from coolant hose bleeder hole.
- Tighten bleeder screw to 15 Nm.

Note: Always replace sealing ring.





- Loosen coolant hose to heater core and pull back hose sufficiently so that bleeder hole (arrow) is no longer sealed by connection.
- Fill with coolant until it escapes from coolant hose bleeder hole.
- Slide coolant hose onto connection sleeve and secure using spring-type clamp.
- 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 lower coolant hose at radiator is hot.

WARNING: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

- Check coolant level and top up if necessary. With engine at operating temperature, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.
- Turn engine off.

Tightening torque