Cooling System: Service and Repair

Draining and Filling

Special tools and workshop equipment required

• Refractometer -T10007-
• Adapter -V.A.G 1274/8-
• Drip Tray -V.A.G 1306-
• Torque Wrench (5-50 Nm) -V.A.G 1331-
• Spring Type Clip Pliers -VAS 5024 A-
• Coolant System Charge Unit -VAS 6096-

Draining

Warning: Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scaling. Cover the cap with a cloth and open carefully.

- Open the cap on the coolant expansion tank.

- Remove the noise insulation, along with the left and right sides.





- Pull the coolant hose retaining clip -arrow- off, downward and remove the coolant hose from radiator.





- In addition, to drain the coolant from the engine, disconnect the coolant hose -arrow- at the oil cooler.

Note: Observe disposal regulations.

Filling

Note:

• Only use coolant additive G 12 according to TL VW 774 F. Identifying feature: violet
• "G12" 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.
• G 12 purple (according to TL VW 774 F) may be mixed with previous coolant additive G 12 red.
• Because of it's high boiling point, the coolant improves engine reliability under heavy loads, particular in countries with tropical climates.
• Protection against frost must be assured to about -25°C (-13°F) (in arctic climate countries to about -35°C (31°F)
• 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 G12 can be increased, but only up to 60% (frost protection to about -40°C (-40°F), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.
• If the radiator, heater core, cylinder head or cylinder head gasket is replaced, do not reuse the old coolant.
• To fill the coolant circuit, use of the coolant system charge unit -VAS 6096- recommended.

Recommended mixture ratios





• The quantity of coolant can vary depending upon vehicle equipment.

Procedure





- Install the lower coolant hose and secure with the retaining clip -arrow-.





- Push the coolant hose -arrow- onto the oil cooler connection and fasten with the spring type clip.

With the cooling system charge unit -VAS 6096-

- Install the adapter -V.A.G 1274/8- on the expansion tank.

- Fill the coolant circuit using the cooling system charge unit -VAS 6096-. Refer to the operating instructions for the cooling system charge unit.

Without the cooling system charge unit -VAS 6096-





- Fill the coolant to the MAX. mark on the expansion tank.

- Install the expansion tank cap.

- Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.

- Allow the engine run at idle speed until the lower coolant becomes hot.

- Check the coolant level and fill as necessary. When the engine is at normal operating temperature, the coolant level must be on the MAX. mark, and when the engine is cold, it must be between the MIN. and MAX. marks.