Volkswagen Workshop Service and Repair Manuals

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

• ◆ Drip tray V.A.G 1306
• ◆ Pliers V.A.G 1921 for spring type clips
• ◆ Anti-freeze tester
• ◆ Cooling system charging unit VAS 6096

Draining

• ‒ Remove cap from coolant expansion tank.

• ‒ → Pull out retaining clip -3-, pull connection -2- off thermostat flange -4- and pull off coolant hose -1- or remove thermostat flange -4-.

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 additives G 11 and 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.
• ◆ When refilling the coolant system only use G 12.

Recommended mixture ratios:

     1)     The amount of anti-freeze must not exceed 60 %; frost protection and cooling effect will decrease if amount of anti-freeze is too high.

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

With cooling system charging unit VAS 6096:

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

Without cooling system charging unit VAS 6096:

• ‒ Press down top radiator hose.

• ‒ → Slowly fill with coolant up to max. mark on expansion tank (filling time approx. 5 minutes).
• ‒ Start engine and run at approx. 1500 rpm for max. 2 minutes and at the same time fill with coolant up to over-flow hole on expansion tank.
• ‒ Fit expansion tank cap.
• ‒ 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.