Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ T10007 Refractometer
• ◆ V.A.G 1306 Drip tray
• ◆ VAS 5024 Assembly tool for spring-type clamps

Not illustrated:

• ◆ VAS 6096 Cooling system charging

Draining

• ‒ Remove cap from coolant expansion tank.
• ‒ Remove noise insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

• ‒ Pull lower coolant hose off radiator connection and drain coolant.

• ‒ → To drain coolant from engine, also remove coolant hose from oil cooler -arrows-.

Note:

Observe disposal regulations!

Filling

Notes:

• ◆ Only use coolant additive G 12 in accordance with TL VW 774 F.
  Distinguishing feature: coloured violet
• ◆ G 12 violet (in accordance with TL VW 774 F) can be mixed with the previous coolant additive G 12 red!
• ◆ G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage, scaling and also raise boiling point of 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.

Recommended mixture ratios:

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

• ‒ Secure lower coolant hose on radiator connection.
• ‒ Connect the coolant hose to oil cooler.
• ‒ Install insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

With cooling system charging unit VAS 6096:

• ‒ Screw adapter from V.A.G 1274 suitable for this vehicle onto expansion tank.
• ‒ Fill coolant circuit using cooling system charging unit VAS 6096.

=> Operating instructions for cooling system charging unit VAS 6096

Without cooling system charging unit VAS 6096:

• ‒ → Fill with coolant up to max. mark on expansion tank.
• ‒ Fit expansion tank cap.
• ‒ Turn off heater control.
• ‒ Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.
• ‒ Run engine until radiator fan cuts-in.
• ‒ Check coolant level and replenish as necessary. When the engine is at normal operating temperature, the coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.