Cooling System: Service and Repair
Draining and Filling
Special tools, testers and auxiliary items required
• Adapter (V.A.G 1274/8)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (V.A.G 1921)
• Cooling System Charge Unit (VAS 6096)
• Refractometer (T10007)
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.
Draining
• Drained coolant must be stored in a clean container for disposal or reuse.
• Follow all disposal regulations.
- Open the cap on the expansion tank.
- Remove the noise insulation.
- Place the drip tray under the radiator.
- Open the spring clamp - 1 - and remove the coolant hose - 2 -.
Filling
Only use distilled water for mixing with G12 plus-plus. Using distilled water provides optimum corrosion protection.
• Only use coolant additive G 12 plus-plus that conforms to TL VW 774 G.
• Coolant additives with the note "conforming to TL VW 774 G" prevent frost, corrosion damage and scaling. They also increase the boiling point. 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 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 a lower freeze protection is necessary due to the climatic conditions, increase the amount of coolant additive. Increase the coolant additive only up to 60% (freeze protection down to approximately -40 °C (-40 °F)). Otherwise the freeze protection and cooling effect are 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 old coolant.
Recommended Mixture Ratios:
• 1 The quantity of coolant can vary depending upon the vehicle equipment.
- Connect the coolant hose - 2 - to the radiator and secure it with the spring clamp - 1 -.
Filling using the Cooling System Charge Unit (VAS 6096) :
- Install the adapter (V.A.G 1274/8) to the expansion tank.
- Fill the coolant circuit using the cooling system charge unit (VAS 6096). Refer to the operating instructions.
Filling without the Cooling System Charge Unit (VAS 6096) :
- Slowly add coolant until it reaches the upper mark - arrow - on the expansion tank.
- Close the expansion tank.
- Turn off the heater and Air Conditioning (A/C).
- Start the engine and maintain an engine speed of approximately 2000 RPM for approximately 3 minutes.
- Let the engine run until the fan starts up.
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.
- Check the coolant level with the expansion tank closed. If more coolant is needed, let the engine cool down and then add.
• At engine operating temperature, the coolant level must be at the upper mark in the shaded area - arrow -.
• When the engine is cold, the coolant level should be in the middle of the shaded area.