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 pictured)

Draining

CAUTION! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.

- Open cap for coolant expansion tank.
- Remove noise insulation.





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





- Remove coolant hose from connection piece - 2 -.
- Remove bolts - 1 -, connection pieces - 2 -, O-ring - 3 - and coolant thermostat - 4 -.

Note: Observe disposal regulations for coolant!

Filling

Note:
^ Only use coolant additive G 12+ (according to TL VW 774 F). Distinguishing feature: colored violet
^ "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.
^ G 12+ (according to TL VW 774 F) may be mixed with previous coolant additive G 12 (red).
^ 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.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.





^ It is recommended to use Refractometer T10007 to determine freezing temperature of coolant.

Recommended mixture ratios:





Note: Use only clean drinking water for mixing.

Work procedure
- Install lower coolant hose and secure.
- Replace O-ring and install coolant thermostat and connection pieces. The coolant thermostat clip must stand vertical.
- Tightening torque: 15 Nm
- Install coolant hose to connection pieces.

With cooling system charge unit VAS 6096





- Screw adapter V.A.G 1274/8 onto expansion tank.
- Fill coolant circuit using cooling system charge unit VAS 6096, Operating instructions for cooling system charge 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 for V.A.G 1274 tester V.A.G 1274/10.
- Peel back protective cover for coolant hose at heat exchanger connection.





- Loosen coolant hose on heater core and pull back hose sufficiently so that the bleed hole in coolant hose - arrow - is no longer covered by the connecting piece.
- Fill up coolant until it escapes from coolant hose bleeder hole.
- Push coolant hose on connection and secure it again.

With and without cooling system charge unit VAS 6096:
- Install coolant reservoir cap.
- Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes.
- Allow engine to run at idle speed until the 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 the cap with a rag and open very carefully.

- Check coolant level and top off if necessary. With engine at operating temperature, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.