VW Golf manuals

Volkswagen Golf Service & Repair Manual: Draining and filling coolant

Draining and filling coolant

Special tools and workshop equipment required
Refractometer -T10007 A-
Drip tray for workshop hoist -VAS 6208-
Hose clip pliers -VAS 6340-
Cooling system charge unit -VAS 6096-
Adapter for cooling system tester -V.A.G 1274/8-
Eye protection
Protective gloves
Cooling system tester -V.A.G 1274 B-

 
Draining
 

Draining and filling coolant

–  Open cap -arrow- on coolant expansion tank.
The cooling system is under pressure when the engine is hot. Hot steam/hot coolant can escape - risk of scalding. Risk of scalding to skin and body parts.Wear protective gloves.Wear eye protection.Release pressure by covering cap of coolant expansion tank with a cloth and opening it carefully.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Set drip tray for workshop hoist -VAS 6208- underneath.
–  Disconnect connector -2- from radiator outlet coolant temperature sender -G83--3-.
 

Draining and filling coolant

–  Lift retaining clip -1-, disconnect coolant hose from radiator (bottom left) and drain off coolant.
 

Draining and filling coolant

–  Lift retaining clip -arrow-, disconnect coolant hose from water radiator (bottom right) for charge air cooling circuit and drain off remaining coolant.
Filling
  Note
The water used in the coolant mixture has a great influence on its effectiveness. Because the water quality differs from country to country and even region to region, the quality of the water to be used has been defined. Distilled water fulfils all requirements. For this reason, we recommend using distilled water when mixing coolant for topping up or replacing coolant.
Use only coolant additives which conform with the → Electronic Parts Catalogue (ETKA). Other coolant additives may reduce corrosion protection substantially. The resulting damage could lead to loss of coolant and subsequent severe damage to the engine.
The correct coolant solution ratio helps prevent damage due to freezing and corrosion as well as scaling. Moreover, the boiling temperature is raised. Therefore, the cooling system must be filled all year round with coolant additive.
Because of its higher boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
 

Draining and filling coolant

ONLY refractometer -T10007A- may be used for determining current anti-freeze value.
Frost protection must be guaranteed down to -25°C as a minimum and, in countries with arctic conditions, down to approx. -36°C. Increasing the frost protection is permissible only if climatic conditions require stronger frost protection. But only to -48°C. Otherwise, the cooling effect of the coolant will be impaired.
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.
Read off anti-freeze figures for respective replenished anti-freeze.
The temperature read off the refractometer -T10007A- equates to the »ice flocculation point«. Ice crystals can start forming in the coolant below this temperature.
Do not reuse old coolant.
Use only a water/anti-freeze mixture as a slip agent for coolant hoses.
Coolant mixture ratio
 

Draining and filling coolant

Frost protection to Coolant additive concentration   Coolant additive 1) Distilled water 1)
-25 °C -36 °C 40 % 50 % 3.2 l 4.0 l 4.8 l 4.0 l
 
1) The quantity of coolant can vary depending on the vehicle equipment.
Coolant: → Electronic Parts Catalogue.
Procedure
–  Connect coolant hose with plug-in connector to radiator (bottom left) → Fig..
   
–  Connect coolant hose to water radiator for charge air cooling circuit (bottom right) -arrow-.
 

Draining and filling coolant

–  Fill coolant reservoir of -VAS 6096- with at least 10 litres of pre-mixed coolant in correct mixture ratio:
–  Screw adapter for cooling system tester -V.A.G 1274/8- onto coolant expansion tank.
–  Place cooling system charge unit -VAS 6096- on adapter -V.A.G 1274/8-.
–  Feed vent hose -1- into a small container -2-.
  Note
Exhaust air takes a slight quantity of coolant along with it; this should be collected.
–  Close valves -A- and -B- (turn lever transverse to direction of flow to do this).
–  Connect hose -3- to compressed air.
Pressure: 6 … 10 bar.
 

Draining and filling coolant

–  Open valve -B-; turn lever in direction of flow to do this.
Vacuum is generated in the cooling system by the suction jet pump; the needle of the gauge must move into green range.
–  Also briefly open valve -A- (turn lever in direction of flow to do this) so that hose on -VAS 6096- coolant reservoir fills with coolant.
–  Close valve -A- again.
–  Leave valve -B- open for a further 2 minutes.
Vacuum continues to be generated in the cooling system by the suction jet pump; the needle of gauge must remain in green range.
–  Close valve -B-.
The needle on the gauge should remain in the green range. The vacuum level in the cooling system is then sufficient for subsequent filling.
  Note
If the needle does not reach the green zone, repeat the process.
If the vacuum drops, the cooling system must be checked for leaks.
–  Pull off compressed air hose.
–  Open valve -A-.
Vacuum in cooling system causes coolant to be extracted from -VAS 6096- coolant reservoir and coolant system to be filled.
–  Remove cooling system charge unit -VAS 6096- from coolant expansion tank.
 

Draining and filling coolant

–  Fill coolant up to “max.” mark.
–  Install noise insulation → General body repairs, exterior; Rep. gr.66.
–  On vehicles with auxiliary heater, switch on auxiliary heater for about 30 seconds.
–  Set temperature regulator to “HI”.
–  Switch off air conditioner compressor (press AC button).
LED in the button must not light up.
–  Start engine and run alternately at approx. 1,500 rpm to a maximum of 2,800 rpm until radiator fan starts operating.
–  Tighten cap of coolant expansion tank until it engages.
–  Switch off engine and let it cool off.
 

Draining and filling coolant

–  Check coolant level.
–  Screw adapter for cooling system tester -V.A.G 1274/8- onto coolant expansion tank.
–  Use cooling system tester -V.A.G 1274 B- to apply a pressure of 1 bar to the cooling system.
–  Use tester to relieve pressure and remove cooling system tester -V.A.G 1274 B-.
–  With the engine running, fill coolant up to approx. 5 mm above max. mark.
The coolant level must be between the “min” and “max” marks when the engine is cold.
The coolant level can be at or above the “max.” mark when the engine is warm.
 

Draining and filling coolant

Coolant hose schematic diagram
  Note The arrows point in the direction of coolant flow. The arrows on the coolant pipes and on the ends of the hoses must ...

Checking cooling system for leaks
Special tools and workshop equipment required     Cooling system tester -V.A.G 1274 B- ...

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