Cooling System, Draining and Filling

Cooling system, draining and filling





Special tools and equipment
^ T10007 Refractometer
^ VAG1306 Drip tray
^ VAS5024 Assembly tool for spring-type clamps

Draining

WARNING: Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open carefully.

- Open cap on coolant expansion tank.
- Remove center insulation tray:





- To drain coolant from radiator remove drain plug -arrow-.





- To drain coolant from engine also remove coolant hose from oil cooler -arrow-.

Note: Observe disposal regulations!

Filling

Note:
^ Only use coolant additive G 12 in accordance with TL VW 774 D. Identification: colored red.
^ On no account must G 12 be mixed with other coolant additives!
^ If the fluid in expansion tank is brown, G 12 has been mixed with other coolant. In this case the coolant must be changed.
^ G 12 and coolant additives marked "In accordance with TL VW 774 D" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with frost and corrosion protection additives.
^ Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
^ Protection against frost must be assured to about -25°C (-13°F) (in arctic climate countries to about -35°C (-31°F)).
^ The coolant concentration must NOT be reduced by adding water even in warmer seasons and in warmer countries. The antifreeze ratio must be at least 40 %.
^ If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only up to 60 % (frost protection to about -40°C(-40°F)), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.





^ The T10007 refractometer is recommended for determining frost protection density.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.





Recommended mixture ratios:
1) The quantity of coolant can vary depending upon the vehicle equipment.





- Screw drain plug into radiator.





- Push coolant hose onto oil cooler connection and secure with a spring type clamp.





Vehicles through Model Year 2001
- Fill with coolant up to max. mark on expansion tank.





Vehicles from Model Year 2002
- Slowly fill expansion tank to upper marking of shaded field with coolant.

Continuation for all vehicles
- Install expansion tank cap.
- Switch off heater and air conditioner.
- Start engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.
- Run engine until coolant fan cuts-in.

WARNING: Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open carefully.

- Check coolant level and top-off if necessary.

Vehicles through Model Year2001
When the engine is at normal operating temperature, the coolant level must be on the max. mark.
When the engine is cold, the coolant level must be between the min. and max. marks.

Vehicles from Model Year 2002
When the engine is at normal operating temperature, the coolant level must be at the upper marking of the shaded field.
When the engine is cold, the coolant level should be at approximately the middle of the shaded field.