Cooling System, Draining and Filling

Cooling system, draining and filling
Special tools and equipment





^ T10007 Refractometer
^ VAG1274/8Adapter
^ VAG 1306 Drip tray
^ VAG 1331 Torque wrench (5...50 Nm)
^ VAS 5024 Installation tool for spring-type clips
^ VAS 6096 Cooling system charging unit

Draining
^ Open cap on coolant expansion tank.

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

^ Remove sound insulation:
^ Remove front bumper:
^ Move lock carrier into service position, Refer to Body and Frame, Radiator Support, Service and Repair [1][2]Procedures
^ Drain coolant from radiator through drain plug.

Note: Observe disposal regulations for coolant!

^ Pull coolant hose retaining clip off downward and remove coolant hose from radiator.
^ Disconnect coolant hose from oil cooler.

Filling

Note:
^ Only use coolant additive G 12 in accordance with TL VW 774 F. Distinguishing feature: violet color
^ 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 anti-freeze ratio 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.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.





^ The refractometer T10007 is recommended for determining the current anti-freeze density.
Recommended mixture ratios:





1) The quantity of coolant can vary depending upon the vehicle equipment.
2) Use only clean drinking water.

Work sequence
^ Install lower coolant hose and secure.
^ Connect coolant hoses on oil cooler.
^ Replace O-ring of coolant drain plug and insert coolant drain plug in cooler again.
Tightening torque: 20 Nm





^ Screw adapter VAG 1274/8 onto expansion tank.
^ Fill coolant circuit using cooling system charging unit VAS 6096.
=> Operating instructions for cooling system charging unit VAS 6096
^ 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 as necessary:
^ When engine is at normal operating temperature coolant level must be on max. mark.
^ When engine is cold coolant level can be between min. and max. marks.
^ Check headlight adjustment and adjust if necessary.