Drain and Fill (Refill) Cooling System

Cooling system, draining and filling

Anti-freeze and coolant additives marked "In accordance with TL VW774 C" prevent freezing, corrosion damage, scale formation and raises the coolant's boiling point. The high boiling point of the coolant mixture helps improve engine efficiency when operating at full load, particularly in tropical climates. The cooling system is filled for use year-round with a mixture of water and anti-freeze coolant additive. If the engine coolant radiator, heater core, cylinder head or cylinder head gasket are replaced, completely replace engine coolant. Do not re-use old coolant.

CAUTION: Dispose of used coolant properly.

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 with a cloth and open carefully to relieve system pressure slowly.

Note:
A new "G12 " coolant additive, recognized by its red color, has been introduced during MY. 1997, replacing the "G11" used previously.
The "G11" and "G12" coolant additives are NOT interchangeable, and must NEVER be mixed. Use only water or "G12" coolant additive G 012A8D A1 to top up cooling systems filled with "G12."
Contamination of "G12" with other coolants can be identified by discoloration (brown, purple, etc.), and foamy deposits in the radiator or expansion tank. If contaminated, the system must be drained and flushed immediately.
"G12" (Part No. G 012 A8D A1) may also be used in older vehicles, but only if the cooling system is drained and flushed as described below
Part numbers listed are for reference only Always check with the Parts Department for the latest information.

Draining

Remove cap from coolant expansion tank.






Remove retaining clip -3- and separate connection -2- from thermostat housing -4-
Remove coolant hose -1- or remove thermostat housing -4-

Flushing procedure

Engine at normal operating temperature (heater valve open where applicable)

Coolant drained

Apply compressed air to expansion tank to help blow out remaining coolant.
Close cooling system, fill with distilled water,then run engine for minimum of 2 minutes.
Drain cooling system and apply compressed air to expansion tank to help blow out remaining water.
Close cooling system and fill with appropriate mixture of "G12" coolant additive and distilled water
Test drive vehicle and top off coolant level if necessary.

Caution: Never reuse old coolant. Dispose of old coolant properly. Coolant G 012 A8D A1 may only be used in older vehicles after the original coolant is drained and the cooling system flushed as described above otherwise engine damage can result.

Part numbers listed are for reference only. Always check with your parts supplier for the latest information.

Antifreeze Mixture Ratio:

Fill level marks on coolant expansion tank:

Fill coolant to MAX mark on expansion tank
Close expansion tank (install cap)
Let engine run until coolant fan -V7- comes on
Check coolant level and top-up if necessary
With engine at operating temperature coolant level must be at MAX mark
With cold engine coolant level must be between MIN and MAX marks.