Page 1 of 40
19-1
Cooling system components,
removing and installing
WARNING!
The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
Notes:
Hoses are secured with spring-type clips. If
servicing, only use the same type of spring-type
clip.
Parts catalog
VAG1921 pliers are recommended when
installing spring-type clips.
The O-rings installed at the quick-release
connections must be replaced if damaged or
leaking.
Seals and gaskets must always be replaced.
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Page 13 of 40
19-11
Cooling system, draining and refilling
Draining
WARNING!
The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
- Open coolant expansion tank cap.
- Remove noise insulation panel.
- Place VAG1306 drip tray underneath engine.
- With bumper removed, open coolant drain plug (arrow) on lower left of
radiator by turning it counterclockwise. If necessary, attach accessory
hose to connection.
-
With bumper installed, pull off retaining clamp for lower right radiator
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Page 19 of 40
19-16
- Raise engine speed to approx. 2000 rpm for
approx. 5 minutes.
- Allow engine to idle until lower coolant hose on
radiator is hot.
- Check coolant level and top-off if necessary.
When engine is at normal operating
temperature, coolant level must be on MAX
mark. When engine is cold, coolant level must
be between MIN and MAX marks.
WARNING!
The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
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Page 34 of 40
19-28
Cooling system, pressure test
Engine at operating temperature
WARNING!
The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
- Open cap on coolant expansion tank.
- Using VAG1274/8 adapter attach VAG1274 cooling system tester to
coolant expansion tank.
- Use tester hand pump to create a pressure of approx. 1.0 bar (14.5
psi).
- If pressure falls, check for leaks and repair.
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