Cooling System, Draining and Filling

Cooling system, draining and filling

Special tools, equipment, testers, measuring instruments and auxiliary items required





^ T10007 Refractometer
^ VAG1306 Drip tray
^ Torque wrench VAG1331
^ VAS5024 Assembly tool for spring-type clamps
^ Adapter for expansion tank VAG1274/8
^ VAS6096 Coolant system charging unit

Draining

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

^ Open cap on coolant expansion tank.
^ Remove sound insulation tray:

^ Place drip tray VAG1306 under vehicle.





^ Remove drain plug (arrow) to drain coolant from radiator.





^ Remove coolant hose from oil cooler (arrow) to drain coolant from engine.

Note: Observe waste disposal regulations!

Filling

Note:
^ Only use coolant additive G 12 in accordance with TL VW 774 F. Distinguishing color: violet
^ G 12 and coolant additives marked "In accordance with TL VW 774 F" 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.
^ G 12 (according to TL VW 774 F) can be mixed with coolant additive G12 which is colored red.
^ 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 (in arctic climatic countries to about -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 anti-freeze is required, the amount of G 12 can be increased, but only up to 60 % (anti-freeze to about -40°C), as otherwise anti-freeze is reduced again and cooling effectiveness is also reduced.





^ Refractometer T10007 is recommended to determine coolant freezing temperature.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.





Recommended mixture ratios:

Work sequence
^ Screw drain plug into radiator.





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





Vehicles with max. expansion tank marking
^ Fill with coolant up to max. mark on expansion tank.
^ Fit 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 starts.
^ Switch off ignition.

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





^ Check coolant level and top up if necessary.
When engine is at normal operating temperature, coolant level must be on max. mark
When engine is cold coolant level must be between min. and max. marks.

Vehicles without max. expansion tank marking





^ Fill coolant slowly up to upper hatched field mark (arrow) on expansion tank.
^ Close expansion tank.
^ 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 starts.
^ Switch off ignition.

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





^ Check coolant level and top up if necessary:
Coolant level must be at upper hatched field mark when engine is at operating temperature (arrow).
When engine is cold coolant level should be around middle of hatched field.

Filling coolant system with charging unit VAS6096
^ Screw adapter VAG1274/8 onto expansion tank.
^ Fill coolant system using coolant system charging unit VAS6096:
^ Instruction manual for coolant system charging unit VAS6096