Cooling System, Draining and Filling

Engine cooling system, draining and filling

Draining

Note:
^ Collect drained coolant in a clean container for re-use or disposal.
^ Coolant must only be mixed with clean drinking water.

- Remove cap from coolant expansion tank.

WARNING!
Hot steam can escape when the cap on the expansion tank is opened. Cover the cap with a cloth, and open it carefully.





- Remove center sound insulation panel.
- Place drip tray V.A.G. 1306 below engine.





- Turn drain screw (arrow) on radiator counter-clockwise (install an extension hose to connection if necessary).





- Also disconnect bottom coolant hose from oil cooler (arrow), and drain remaining coolant.

Filling

Note:
^ Only use coolant additive G 012 A8 D which meets specification TL VW 774 D (identifiable by red color).

CAUTION
Do not use G 011 A8 C. The two different coolant additives G 011 A8 C and G 012 A8 D must not be mixed together. Otherwise this can result in serious damage to the engine.

^ If the fluid in the expansion tank is brown it means G 012 A8 D has been mixed with another type of coolant. In this case, flush out the cooling system and put in fresh coolant. To flush the system, fill it with clean drinking water and run the engine for about 2 minutes. This should remove very nearly all of the old coolant.
^ G 012 A8 D and coolant additives marked "meeting specification TL VW 774 D" prevent frost and corrosion damage, stop scaling, and at the same time raise the boiling point of coolant. For these reasons the cooling system must be filled all year round with the correct anti-freeze and anti-corrosion additive.
^ Because of its high boiling point, the cooling improves engine reliability under heavy loads, particularly in countries with tropical climates.
^ Frost protection is required down to about -25 degrees C (or to about -35 degrees 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 anti-freeze ratio must be at least 40%.
^ If greater frost protection is required in very cold climates, the amount of G 012 A8 D can be increased, but only up to 60% (this gives frost protection to about -40 degrees C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
^ If the radiator, heat exchanger, cylinder head or cylinder head gasket are replaced, do not re-use old coolant.





Note:
Use clean drinking water in addition to coolant to top off cooling system.

- Screw in coolant drain plug.





- Top up coolant to max. mark on expansion tank.
- Start engine and run at approx. 1500 rpm for max. 2 minutes and at same time fill with coolant up to overflow hole on expansion tank.
- Install expansion tank cap.
- Run engine until coolant fan cuts in.
- Stop engine.
- Check coolant level and top-up if necessary.

^ When the engine is at normal operating temperature, the coolant level must be on the max. mark
^ When the engine is cold, coolant level must be between the min. and max. marks

WARNING!
Hot steam can escape when the cap on the expansion tank is opened. Cover the cap with a cloth, and open it carefully.