Cooling System, Draining and Filling

Cooling system, draining and filling





Special tools and equipment
^ T10007 Refractometer
^ VAG1274/8 Adapter
^ VAG1306 Drip tray
^ VAG1331 Torque wrench (5 50 Nm)
^ VAS 5024 Assembly tool for spring-type clips

Not illustrated:
^ VAS 6096 Coolant system charging unit

Draining
- Open cap on coolant expansion tank.

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

- Remove center insulation tray





- Pull out lower coolant hose retaining clip -arrow- and remove coolant hose from radiator.





- To drain coolant from engine also remove coolant hoses from oil cooler -arrows-.

Note: Observe waste disposal regulations!

Filling

Note:
^ Only use coolant additive G 12 in accordance with TL VW 774 D. Identification color: red
^ Under no circumstances must G 12 be mixed with other coolant additives!
^ If the fluid in expansion tank is brown, G 12 has been mixed with another 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 the 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 approximately -25°C (in arctic climatic countries to approximately -35°C).
^ 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 for climatic reasons a higher frost protection is required, the amount of G 12 can be increased but only up to 60% (frost protection to about -40 ^C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
^ Refractometer T10007 is recommended for determining the current density of the antifreeze.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket are replaced, do not reuse old coolant.





Recommended mixture ratios:
1) The quantity of coolant can vary in accordance with the equipment fitted to the vehicle.





Work sequence
- Install lower coolant hose and secure with retaining clamp -arrow-.





- Slide coolant hoses onto oil cooler unions -arrows- and secure with spring-type clamps.
- Install center insulation tray





Without using coolant system charging unit VAS 6096
- Fill coolant slowly up to top mark of hatched field on expansion tank.

Using coolant system charging unit VAS 6096
- Screw adapter V.A.G1274/8 onto expansion tank.
- Fill coolant system using coolant system charging unit VAS 6096:
=>See instruction manual for coolant system charging unit VAS 6096

With and without coolant system charging unit VAS 6096
- Seal expansion tank.
- Switch off heater and air conditioner.
- Start engine and maintain an engine speed of about 2000 rpm for approximately 3 minutes.
- Allow engine to run at idling speed until lower hose on radiator becomes hot.
- Switch ignition off.





- Check coolant level and top up coolant if necessary:
At normal engine operating temperature coolant level must reach top mark of hatched field.
When engine is cold coolant level should be around middle of hatched field.