Procedures

Cooling system, draining and filling





Special tools, testers and auxiliary items required
^ Refractometer T10007
^ Drip Tray V.A.G 1306 or Drip Tray for VAS 6100 VAS 6208
^ Spring-type clip pliers VAS 5024A
^ Cooling system charge unit VAS 6096

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 sound insulation tray.





- Remove drain plug - arrow - to drain coolant from radiator.





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

Note: Observe disposal regulations!

Filling

Note:
^ Only use coolant additive G 12 (according to TL VW 774 D). Distinguishing feature: red color
^ G 12 must not be mixed with any other coolant additives under any circumstances!
^ The fluid in the reservoir is brown, G 12 was mixed with another coolant. In this case, the coolant must be replaced.
^ G 12 and coolant additives marked in accordance with "TL VW 774 D " 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 clean 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.





^ The Refractometer T10007 is recommended for determining anti-freeze density.
^ If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.
Recommended mixture ratios:









- Install drain plug in radiator.





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

Using cooling system filler unit VAS 6096:
- Install adapter from Cooling System Tester V.A.G 1274 that is appropriate for vehicle on reservoir.
- Fill coolant circuit using cooling system filling unit VAS 6096 Operating instructions for cooling system filling unit VAS 6096.

Without cooling system filler unit VAS 6096:

Model year 2001 vehicles





- Fill coolant to Max marking on expansion tank.

Model year 2002 vehicles





- Slowly fill coolant up to top marking of hatched area on expansion tank.

Continuation for all vehicles
- Seal expansion tank.
- Turn off the heater and air conditioning.
- Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes. Allow engine to run until fan turns on.

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.

Model year > 2001 vehicles
- 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.

Model year 2002 > vehicles
With engine at operating temperature, coolant level must lie at top marking of hatched area.

When engine is cold, the coolant level should be somewhere in the middle of hatched area.