Coolant, Draining And Filling

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Refractometer T10007A
Shop Crane - Drip Tray VAS6208
Hose Clip Pliers VAS6340
Cooling System Charge Kit VAS6096
Cooling System Tester - Adapter VAG1274/8
Protective eyewear
Protective gloves

Draining

WARNING:

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

-- Remove the cap -1- from the coolant reservoir.

Fig 1: Identifying Coolant Reservoir

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the noise insulation, refer to Overview - Herbie Beetle Decorative Film .

-- Place the Shop Crane - Drip Tray VAS6208 underneath.

-- Lift the clamp -1-, remove the lower left coolant hose from the radiator.

Fig 2: Identifying Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Allow the coolant to drain.

-- Lift the clamp -2- and remove the lower right coolant hose from the charge air cooling circuit cooler.

-- Allow the coolant to drain.

-- Loosen the hose clamp -arrow-, remove the lower coolant hose to the Heater Support Pump - V488-.

Fig 3: Identifying Hose Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Allow the coolant to drain.

-- Remove the coolant hose from the Charge Air Cooling Pump -V188- -5-.

Fig 4: Identifying Charge Air Cooling Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Allow the coolant to drain.

CAUTION:

The engine could be damaged through uneven filling/bleeding of the coolant system.

The cooling system must be bleed after filling, refer to Vehicle Diagnostic Tester.

NOTE:

The water portion of the coolant influences the effectiveness of the coolant. Based on the contents, the country or even the region specific quality can be different. Use distilled water. For this reason, we recommend using distilled water when adding coolant or filling coolant for the first time.

Use only coolant additives listed in the Parts Catalog. Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage.

Coolant with the correct mixture ratio prevents freezing and corrosion damage and calcium deposits. The boiling point will be raised. The cooling system must be filled with coolant additive year-round.

Because of its high boiling point, the coolant contributes to engine reliability under heavy loads, particularly in countries with tropical climates.

The Refractometer T10007A MUST be used to determine the freeze protection value.

Fig 5: Identifying Freeze Protection Value On Scale

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Protection against frost must be assured down to minimum -25 °C (-13 °F) (in arctic climatic countries down to approximately -36 °C (-32.8 °F)). When stronger freeze protection is needed due to the climate, the freeze protection may be increased. But only up to -48 °C (-54 °F), otherwise the effectiveness of the coolant decreases.

The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The frost protection must be at least -25°C (-13 °F).

Read the freeze protection value on the scale for the coolant additive that has been added.

The temperature on the Refractometer T10007A corresponds to the >>freezing point<<. At this temperature, ice crystals may begin to form in the coolant.

Do not reuse used coolant.

Only use water/coolant additive to lubricate the coolant hoses.

Coolant Mixture Ratio

Coolant additive (40%) and distilled water (60%) for freeze protection down to -25 °C
Coolant additive (50%) and distilled water (50%) for freeze protection down to -36 °C
Coolant additive, refer to Parts Catalog.

Procedure

-- Connect the coolant hoses to the connection on the radiator, refer to Figure.

-- Connect the coolant hoses, refer to CONNECTION DIAGRAM - COOLANT HOSES .

-- Fill the coolant reservoir on the Cooling System Charge Kit VAS6096 with at least 8 liters of premixed coolant with the proper mixture ratio.

Fig 6: Filling Coolant Reservoir Of Cooling System Charge Unit VAS 6096

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Cooling System Tester - Adapter VAG1274/8 on the coolant expansion tank.

-- Mount the Cooling System Charge Kit VAS6096 on the Cooling System Tester - Adapter VAG1274/8.

-- Place the air outlet hose -1- in a small container -2-.

NOTE:

A small amount of coolant which should be collected is drawn off with the discharged air.

-- Close valves -A- and -B- by turning lever at a right angle to direction of flow.

-- Connect the hose -3- to compressed air.

Pressure: 6 to 10 bar (87 to 145 psi) pressure.

-- Open valve -B- by turning level in direction of flow.

Fig 7: Identifying Cooling System Draining And Filling

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

A further vacuum is created in the cooling system by the suction jet pump.
Needle on the instrument display must travel into the green region.

-- Briefly open valve -A- by turning lever in direction of flow so that hose on the Cooling System Charge Kit VAS6096 coolant reservoir fills with coolant.

-- Close valve -A- again.

-- Leave valve -B- open another two minutes.

More pressure is generated in the coolant system by the suction jet pump; indicator on display instrument must stay in green area.

-- Close valve -B-.

Needle in the display instrument must remain in the green region, then the sufficient vacuum in the cooling system is obtained for the upcoming filling.

NOTE:

Repeat the procedure if the needle goes below the green range.

If pressure falls, check coolant system for leaks.

-- Remove pressurized air hose.

-- Open valve -A-.

Coolant is extracted from the Cooling System Charge Kit VAS6096 coolant reservoir by pressure in the coolant system and the system is filled.

-- Remove the Cooling System Charge Kit VAS6096 from the coolant reservoir.

-- Fill the coolant to the MAX marking.

Fig 8: Identifying Expansion Tank Upper Hatched Field Mark

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

-- Install the noise insulation, refer to Exterior Equipment .

-- If the vehicle has a parking heater, switch it on for about 30 seconds.

-- Set the temperature at "HI".

-- Press AC to turn off the A/C compressor.

The LED in the button must not come on.

--Connect the Vehicle Diagnostic Tester.

-- Turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

01 - Engine electronics
Guided functions
01 - Cooling system filling/bleeding

-- Follow the instructions given in the Vehicle Diagnostic Tester.

-- Let the engine cool.

-- Check the coolant level.

Fig 9: Identifying Expansion Tank Upper Hatched Field Mark

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The coolant level must be between the min mark and the max markings when the engine is cold.
Coolant level may be at the MAX marking with engine at operating temperature.

-- Add more coolant if necessary.