Volkswagen Workshop Service and Repair Manuals

Draining and filling coolant

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Hose clip pliers -VAS 6340-

t	Cooling system charge unit -VAS 6096-

Draining   WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove noise insulation or underride guard → General body repairs, exterior; Rep. gr.50. Drain coolant from engine cooling system

–  Pull off retaining clip -arrow- and remove coolant hose from radiator.   Note Observe environmental regulations for disposal.

Draining coolant from charge air cooling system –  Pull coolant hose (quick-release coupling) -arrow- off lower connection of auxiliary radiator for charge air system.   Note Observe environmental regulations for disposal. Filling   Note t  The amount of water used in the coolant mixture has a great influence on its effectiveness. Because the water quality differs from country to country and even region to region, Volkswagen has decided to define the quality of the water to be used in the coolant system. Distilled water fulfils all requirements. t  Use only coolant additives in accordance with the → Electronic parts catalogue (ETKA). Other coolant additives may reduce corrosion protection substantially. The resulting damage could lead to loss of coolant and subsequent severe damage to the engine. t  The correct coolant solution ratio → Anchor helps prevent damage from freezing and corrosion as well as scaling. Moreover, the boiling temperature is raised. Therefore, the cooling system must be filled all year round with coolant additive. t  Because of its higher boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. t  The frost protection must be guaranteed to approx. -25 °C. t  Frost protection must be guaranteed down to approx. -35°C in countries with Arctic climates. t  The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive concentration must be at least 40%. t  If a stronger anti-freeze mixture is necessary due to harsher weather conditions, the coolant additive content can be increased. However, this is only permitted to 60% (antifreeze protection to about -40°C). Otherwise, the antifreeze protection will be reduced again and the cooling effect will be impaired. t  If radiator, heat exchanger, cylinder head or cylinder head gasket is renewed, do not reuse old coolant. t  The Refractometer -T10007A- is recommended for determining the current anti-freeze density.   Caution Only distilled water may be used for mixing with coolant additives. The use of distilled water ensures optimum protection against corrosion. Recommended mixing ratios (use only distilled water for mixing):

Frost protection to	Amount of anti-freeze	Coolant additive → Remark	Distilled water → Remark
-25 °C -35 °C	40 % 50 %	2.25 l 2.8 l	3.35 l 2.8 l

1)  The quantity of coolant can vary depending upon vehicle equipment.

–  Press connection against radiator and slide retaining clip -arrow- into groove. –  Install noise insulation or underride guard → General body repairs, exterior; Rep. gr.50. With cooling system charge unit -VAS 6096- –  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- –  Switch off heating and air conditioning system.

–  Fill with coolant up to max. mark on expansion tank. –  Connect → Vehicle diagnostic tester and perform guided function „Filling and bleeding cooling system“.   WARNING Steam may escape when expansion tank is opened. Wear eye protection and protective clothing to avoid eye injuries and scalding. Cover cap with cloth and open carefully. –  Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the coolant level must be at the max. mark; when the engine is cold, between the min. and max. marks.