Volkswagen Workshop Service and Repair Manuals

Draining and filling coolant

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS 6208-

t	Spring-type clip pliers -VAS 5024A-

Draining   WARNING Hot steam may escape when expansion tank is opened. Place rag over cap and open with caution. –  Open cap on coolant expansion tank. –  Remove noise insulation tray: → Rep. Gr.50.

–  To drain coolant from radiator, open drain plug -arrow-.

–  To drain coolant from engine, also remove coolant hose from oil cooler -arrow-.   Note Observe environmental regulations for disposal. Filling   Note t  Use only coolant additive G 12 in accordance with TL VW 774 F. Identification: purple colour. t  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. Therefore, the cooling system must be filled all year round with frost and corrosion protection additives. t  G 12 purple (in accordance with TL VW 774 F) can be mixed with the previous coolant additive G 12 red! t  Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. t  Frost protection is required down to about -25° C (in countries with arctic climates: down to about -35° C). t  The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The frost protection additive must be at least 40% of mixture. t  If for climatic reasons greater frost protection is required, the amount of G 12 can be increased, but only up to 60% (frost protection to about -40°C). Otherwise frost protection and cooling effectiveness are reduced again. t  If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant. t  The refractometer -T10007- is recommended for determining the current anti-freeze density. Recommended mixture proportions:

Frost protection to	Anti-freeze quantity	G 12 → Note	Water → Note
-25° C	40 %	2.0 l	3.0 l
-35 °C	50 %	2.5 l	2.5 l

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

–  Screw drain plug into radiator -arrow-.

–  Push coolant hose onto oil cooler union -arrow- and secure hose with a spring-type clip.

–  Fill with coolant up to max. mark on expansion tank. –  Fit expansion tank cap. –  Start engine and maintain an engine speed of about 2000 rpm for about 3 minutes. –  Run engine until radiator fan cuts-in.   WARNING Hot steam may escape when expansion tank is opened. Place rag over cap and open with caution. –  Check coolant level and top-up if 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.