Cooling system, draining and filling

WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Cooling System, Draining And Filling

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Refractometer T10007
Adapter V.A.G 1274/8
Drip tray V.A.G 1306
Torque wrench V.A.G 1331

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 cap with a rag and open carefully.

Open cap on coolant expansion tank.
Remove sound insulation pan, along with left and right sides: Refer to 50 BODY, FRONT

Fig 2: Locating Coolant Hose Retaining Clip

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Pull coolant hose retaining clip - arrow - off downward and remove coolant hose from radiator.

Fig 3: Locating Coolant Hose At Oil Cooler

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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 F". Distinguishing feature: colored violet
"G 12" and coolant additives marked in accordance with "TL VW 774 F" 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.
G 12 purple (according to TL VW 774 F) may be mixed with previous coolant additive G 12 red!
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%.
Use only clean drinking water for mixing.
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.
To fill the coolant circuit, use of the cooling system charge unit VAS 6096 recommended.

Recommended mixture ratios:

Frost protection to	Anti-freeze portion	G 12 * See note	Clean water * See note
-25 ° C -35 ° C	40% 50%	3.7 l 4.6 l	5.5 l 4.6 l

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

Work procedure

Fig 4: Locating Coolant Hose Retaining Clip

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install lower coolant hose and secure with retaining clamp - arrow -.

Fig 5: Locating Coolant Hose At Oil Cooler

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

With cooling system charge unit VAS 6096

Thread adapter V.A.G 1274/8 on expansion tank.
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

Fig 6: Markings On Coolant Expansion Tank

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Fill coolant to Max marking on expansion tank.
Close 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 at idle speed until the lower hose on radiator becomes hot.
Check coolant level and top off as necessary. When the engine is at normal operating temperature, the coolant level must be on the Max. mark, and when the engine is cold, between the Min. and Max. marks.