Cooling System: Service and Repair
Coolant, Draining and Filling
Special tools, testers and auxiliary items required
• Refractometer (T10007)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Cooling System Charge Unit (VAS 6096)
• Adapter (V.A.G 1274/8)
Draining
Risk of scalding due to hot steam and hot coolant:
• The coolant system is under pressure when the engine is warm.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the coolant expansion tank cap.
- Remove the noise insulation..
- Remove the charge air hose by loosening the clamps - 1 and 2 -.
- Seal off the connection on the charge air cooler with a clean cloth.
• Collect any leaking coolant in a clean container for disposal or reuse.
- Place the drip tray for VAS 6100 (VAS 6208) under the engine.
- Remove the lower coolant hose - 1 - from the radiator and let the coolant drain.
- Remove the lower coolant hose to the after-run coolant pump - arrow - and allow the coolant to drain.
Filling
• The water portion of the coolant influences the effectiveness of the coolant.
• Volkswagen has decided to define the water quality used in the cooling system based on the different mixtures, countries and regional requirements.
• For this reason, we recommend using distilled water for older models when adding coolant or filling the coolant for the first time.
• Always use distilled water.
Only use distilled water for mixing with G12 plus-plus. Using distilled water provides optimum corrosion protection.
• Only use G 12 plus-plus in accordance with TL VW 774 G as a coolant additive.
• Coolant additive with the note "conforming to TL VW 774 G" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. The cooling system must be filled with coolant additive year round.
• 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 down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -35 °C (-31 °F)).
• 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 greater frost protection is required for climatic reasons, the amount of coolant additive can be increased, but only up to 60% (frost protection down to approximately -40 °C (-40 °F)), otherwise frost protection and cooling effectiveness will be reduced.
• The refractometer (T10007) is recommended for determining freeze protection density.
• If the radiator, heater core, cylinder head or cylinder head gasket is replaced, do not reuse the old coolant.
Recommended Mixture Ratios
• 1 The amount of coolant may vary depending on the vehicle equipment.
- Connect the lower coolant hose - 1 - to the radiator.
- Connect the coolant hose to the after-run coolant pump - arrow -.
- Install the charge air hose and clamps - 1 and 2 -.
- Install the noise insulation..
Filling using the Cooling System Charge Unit (VAS 6096)
- Install the adapter (V.A.G 1274/8) to the coolant expansion tank.
- Fill the coolant circuit using the cooling system charge unit (VAS 6096). Refer to the Operating instructions for cooling system charge unit.
Filling without the Cooling System Charge Unit (VAS 6096)
- Slowly fill the coolant up to the top mark of the hatched area - arrow - on the coolant expansion tank.
- Close the coolant expansion tank cap.
- Turn off the Air Conditioning (A/C) and the heater.
- Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.
- Allow the engine to run until the coolant fan starts running.
Risk of scalding due to hot steam and hot coolant:
• The coolant system is under pressure when the engine is warm.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Close the coolant expansion tank cap and check the coolant level. Fill the coolant when the engine is cold, if necessary.
• With the engine at operating temperature, the coolant level must lie at the top mark of the hatched area - arrow -.
• With the engine cold, the coolant level should be located approximately in the center of the hatched area.