Cooling System, Draining and Filling
Cooling system, draining and filling
Special tools and equipment
^ T10007 Refractometer
^ VAG1306 Drip tray for VAG 1 202A
^ VAS 5024 Assembly tool for spring-type clip or VAG1921 Spring clip pliers
Draining
WARNING: Steam can be released when cap is removed from expansion tank. Cover cap with a cloth and open carefully.
- Open cap on coolant expansion tank.
- Remove lower insulation tray
- Unscrew radiator drain plug to drain engine coolant -arrow
- To drain coolant from engine also remove coolant hose from oil cooler -arrow-.
WARNING: Observe proper antifreeze disposal regulations!
If the cooling system was filled with G 11 antifreeze -colored green- or other coolant additive different from G 12:
- Cooling system must be flushed out as follows before reinstalling coolant hoses and filling with new G 12 coolant additive -colored red-.
- Remove as much of remaining coolant as possible from cooling system by, for example, blowing compressed air into coolant expansion tank.
- Connect hoses, fill cooling system with plain water and refit cap.
- Run engine at idling speed for approximately 2 minutes.
- Drain off coolant and blow out cooling system again with compressed air.
WARNING: Observe proper antifreeze disposal regulations!
Filling
Note:
^ Only use G 12 coolant additive. Identification: red color
^ Do not mix G 12 with any other coolant additives!
WARNING: The coolant additives -G11- and -G12- cannot be mixed. If they are mixed it can lead to serious engine damage.
^ If the fluid in expansion tank is brown; G 12 has been mixed with another coolant. Drain the system and replace with fresh engine coolant.
^ G 12 prevents frost and corrosion damage, scaling and also raises the boiling point of the engine coolant. For these reasons, the system must tee filled year round with G12..
^ The higher boiling point of the coolant will improve reliability of engines when heavily loaded in regions with tropical climates, .
^ Protects against freezing to approximately -25°C (17°F) or approximately -35°C (-31°F) in arctic climates.
^ Do NOT reduce the coolant concentration by adding water even in warmer seasons in warm countries. The anti-freeze ratio must be 40 % minimum.
^ If for climatic reasons, greater frost protection is required, the G 12 concentration can be increased but only up to 60% maximum (freeze protection to approximately -40°C or -40°F), otherwise, freeze protection as well as cooling effectiveness will be reduced.
^ The T10007 refractometer is recommended for determining frost prevention thickness
^ If the radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, you must replace all engine coolant with new coolant.
Recommended mixture ratios:
1) Coolant quantity can vary depending upon vehicle equipment.
- Screw in engine coolant drain plug.
- Connect hose to oil cooler.
- Fill expansion tank slowly with coolant up to upper mark of hatched area.
- Install expansion tank cap.
- Turn off A/C (if equipped) and heater.
- Start engine and run at increased idling speed (about 2000 RPM) for approximately 3 minutes.
- Run engine until radiator fan starts.
WARNING: Steam can be released when the cap is removed from the expansion tank. Cover cap with a cloth and open carefully.
- Check coolant level and top-up if necessary.
^ When the engine is at normal operating temperature, the coolant level must be within the hatched area, and when the engine is cold, above the Min. Mark.
- Install lower insulation tray