Procedures
Cooling system, draining and filling
Special tools, testers and auxiliary items required
^ Refractometer T10007
^ Drip tray V.A.G 1306
^ Torque wrench V.A.G 1331
^ Spring-type clip pliers VAS 5024
^ Adapter V.A.G 1274/8
^ Adapter V.A.G 1274/10
^ Cooling system charge unit VAS 6096 (not illustrated)
Draining
CAUTION! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a rag and open carefully.
- Open cap for coolant expansion tank.
- Remove sound insulation.
- Pull coolant hose retaining clip - arrow - off downward and remove coolant hose from radiator.
- Or remove left front ventilation grille and remove drain plug from radiator, for all vehicles.
- Drain coolant from engine through drain plug - arrow -.
Note: Observe disposal regulations for coolant!
Filling
Note:
^ Only use coolant additive G 12 (according to TL VW 774 F). Distinguishing feature: violet color
^ G 12 violet (according to TL VW 774 F) may be mixed with previous coolant additive G 12 red!
^ "G 12" and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage, scaling and also raise the boiling point of the 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 (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 coolant additive portion 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), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
^ It is recommended to use Refractometer T10007 to determine freezing temperature of coolant.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:
Work sequence
- Replace coolant drain plug O-ring and re-install plug - arrow - into engine.
- Tightening torque: 20 Nm
- Install lower coolant hose and secure using retaining clamp - arrow -. Screw in drain plug and install ventilation grille.
With cooling system charge unit VAS 6096
- Thread adapter V.A.G 1274/8 on expansion tank.
- Fill cooling system using cooling system filling unit VAS 6096 Operating instructions for cooling system filler unit VAS 6096.
Without cooling system charge unit VAS 6096
- Screw adapter V.A.G 1274/8 on expansion tank and extend it using adapter V.A.G 1274/10.
- Loosen both bleeder screws on coolant pipes.
- Move back protective cover for coolant hose at connection of heater core.
- Loosen coolant hose on heater core and pull back hose sufficiently so that bleed hole in coolant hose - arrow - is no longer covered by connecting piece.
- Fill with coolant until it flows out of coolant hose bleed hole and out of bleeder screws on coolant pipes.
- Slide coolant hose onto connecting piece and secure it again.
- Tighten bleeder screws on coolant pipes.
- Tightening torque: 20 Nm
Continued - with and without cooling system filler unit VAS 6096
- Close expansion tank.
- Turn off heater and air conditioning.
- Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.
- Allow engine to run at idle speed until lower hose on radiator becomes hot.
CAUTION! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a rag and open carefully.
- Check coolant level, top up if necessary.
- When engine is at normal operating temperature, coolant level must be on Max. mark, and when engine is cold, between Min. and Max. marks.