Page 585 of 708
Fig . 1 U nder t h e b on net: m ark in gs o n t h e c o o la n t e xp an sio n t a n k.
F ig . 2 U nder t h e b on net: c o ola n t e xp an sio n t a n k c a p (il lu stra tio n ).
P re p ara tio ns
C he ck ing t he c o ola nt l e ve l a nd r e fil ling c o ola nt
Page 586 of 708

—Park t h e v e h ic le o n a f ir m a n d l e ve l s u rf a ce .
—A llo w t h e e le ctric d riv e t o c o ol d ow n → .
—Open t h e b on net (→ In t h e e n gin e c o m part m en t).
—Th e c o ola n t e xp an sio n t a n k is id en tif ie d b y t h e s y m bol o n t h e c a p → Fig . 2.
C heck in g t h e c o ola n t l e ve l
Th e e n gin e c o ola n t m ay b e a b ove t h e m ark e d a re a u p on d eliv e ry (n ew v e h ic le s). T h is is n orm al.
T h e c o ola n t d oes n ot h ave t o b e s u cke d o ff.
—C heck t h e c o ola n t l e ve l a t t h e s id e m ark in gs o f t h e c o ola n t e xp an sio n t a n k w hen t h e e le ctric
d riv e is c o ld → Fig . 1. T h e c o ola n t l e ve l m ust b e b etw een t h e m ark s.
—R efil l c o ola n t if t h e l iq uid l e ve l in t h e c o ola n t e xp an sio n t a n k is b elo w t h e m in im um m ark in g
(“ m in ”). W hen t h e e n gin e is w arm , t h e e n gin e c o ola n t l e ve l m ay b e s lig htly a b ove t h e u p per
m ark .
A ddin g c o ola n t
Th e w arn in g l a m p f o r t h e c o ola n t w il l l ig ht u p if t h e c o ola n t l e ve l is t o o l o w . I n t h is c a se , s e ek
sp ecia lis t a ssis ta n ce im med ia te ly .
O bse rv e t h e f o llo w in g if t h e c o ola n t l e ve l is t o o l o w a n d t h ere is n o q ualif ie d w ork sh op in t h e
n ear v ic in it y :
—A lw ays p ro te ct y o ur f a ce , h an ds a n d a rm s f ro m h ot c o ola n t o r s te am b y p la cin g a s u it a b le
c lo th o n t h e c a p o f t h e c o ola n t e xp an sio n t a n k.
—U nsc re w t h e c a p c a re fu lly → .
—Refil l o n ly n ew c o ola n t a cco rd in g t o t h e V olk sw ag en s p ecif ic a tio n (→ Coola n t).
—O nly r e fil l c o ola n t if t h ere is s til l a r e m ain in g q uan tit y o f c o ola n t in t h e e xp an sio n t a n k. I f t h is
is n ot o b se rv e d , t h e e n gin e c o uld b e d am ag ed . I f y o u c a n not s e e a n y c o ola n t in t h e e xp an sio n
ta n k d o n ot d riv e o n. S e ek e xp ert a ssis ta n ce .
—If t h ere is s til l a r e sid ual q uan tit y o f c o ola n t in t h e c o ola n t e xp an sio n t a n k, a d d c o ola n t u p t o
th e u p per l e ve l m ark in g a n d c h eck a ft e r o n e d ay. I f t h e l e ve l d ro p s a g ain, p le ase v is it a
q ualif ie d w ork sh op a n d h ave t h e c o olin g s y ste m c h ecke d .
—Th e c o ola n t l e ve l m ust b e b etw een t h e m ark s o n t h e c o ola n t e xp an sio n t a n k → Fig . 1. D o n ot
fil l a b ove t h e t o p e d ge o f t h e m ark e d a re a → .
—Scre w t h e c a p c lo se d t ig htly .
—If in a n e m erg en cy y o u d o n ot h ave a cce ss t o c o ola n t w it h t h e r e q uir e d s p ecif ic a tio n , d o n ot
u se a n y o th er c o ola n t a d dit iv e (→ Coola n t)! I n ste ad , in it ia lly r e fil l w it h dis til le d w ate r →
on ly . T h en a d d t h e c o rre ct p ro p ort io n o f t h e s p ecif ie d c o ola n t a d dit iv e a s s o on a s p ossib le (→
C oola n t).
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WAR N IN G
Hot s te am a n d h ot c o ola n t c a n c a u se s e rio us b urn s.
●N eve r o p en t h e b on net if y o u c a n s e e o r h ear s te am o r c o ola n t c o m in g o ut o f t h e f ro n t
co m part m en t. A lw ays w ait u n til y o u c a n n o l o n ger s e e o r h ear e sc a p in g s te am o r c o ola n t.
H ot c o m pon en ts c a n b urn t h e s k in .
●Th e f o llo w in g m ust b e o b se rv e d b efo re o p en in g t h e b on net:
●S w it c h o n t h e e le ctro n ic p ark in g b ra ke .
●A lw ays k e ep c h il d re n a w ay f ro m t h e f ro n t c o m part m en t a n d n eve r l e ave t h em
u n su p erv is e d .
●Th e c o olin g s y ste m is u n der p re ssu re w hen t h e e n gin e is h ot. N eve r o p en t h e c a p o f t h e
co ola n t e xp an sio n t a n k w hen t h e e n gin e is h ot. C oola n t m ay s p ra y o ut a n d c a u se s e rio us
b urn s a n d o th er in ju rie s.
●T u rn t h e c a p s lo w ly a n d v e ry c a re fu lly a n tic lo ck w is e w hil e e xe rt in g g en tle d ow nw ard
p re ssu re o n t h e c a p .
●A lw ays p ro te ct t h e f a ce , h an ds a n d a rm s f ro m h ot c o ola n t o r s te am w it h a l a rg e, t h ic k
clo th .
N OTIC E
●R efil l o n ly w it h d is til le d w ate r. A ll o th er t y p es o f w ate r c a n c a u se c o rro sio n in t h e e n gin e
due t o t h e c h em ic a l c o m pon en ts c o n ta in ed in t h e w ate r. T h is c a n a ls o l e ad t o e n gin e f a il u re .
If a n y o th er t y p e o f w ate r is r e fil le d , t h e f lu id in t h e c o olin g s y ste m s h ould b e c o m ple te ly
r e p la ce d im med ia te ly b y a q ualif ie d w ork sh op .
●D o n ot f il l c o ola n t a b ove t h e t o p o f t h e m ark e d a re a → Fig . 1. O th erw is e t h e e xce ss c o ola n t
w il l b e p re sse d o ut o f t h e c o olin g s y ste m w hen t h e e n gin e is h ot a n d c o uld c a u se d am ag e.
●If a l a rg e a m oun t o f c o ola n t h as b een l o st, d o n ot r e fil l t h e c o ola n t u n til t h e e n gin e h as
co ole d c o m ple te ly. H eavy c o ola n t l o ss is a n in dic a tio n o f l e aks in t h e c o olin g s y ste m . T h e
co olin g s y ste m s h ould b e c h ecke d b y a q ualif ie d w ork sh op a s s o on a s p ossib le . F ail u re t o d o
so c a n r e su lt in e n gin e d am ag e.
●D o n ot r e fil l c o ola n t if t h ere is n o m ore c o ola n t in t h e c o ola n t e xp an sio n t a n k. A ir c o uld h ave
e n te re d t h e c o olin g s y ste m . D o n ot d riv e o n ! S e ek e xp ert a ssis ta n ce . F ail u re t o d o s o c a n
re su lt in e n gin e d am ag e.
●W hen r e fil lin g s e rv ic e f lu id s, p le ase e n su re t h at y o u p our t h e c o rre ct s e rv ic e f lu id s in to t h e
co rre ct o p en in gs. T h e u se o f in co rre ct s e rv ic e f lu id s c a n r e su lt in s e rio us m alf u n ctio n s a n d
d am ag e t o t h e e le ctric d riv e .
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Coola n t
Th e in dic a to r l a m p f la sh es r e d .
E ngin e c o ola n t t e m pera tu re t o o h ig h o r e n gin e c o ola n t l e ve l t o o l o w .
Do n ot d riv e o n !
Sto p t h e v e h ic le a s s o on a s p ossib le a n d w hen s a fe t o d o s o .
—D eactiv a te t h e v e h ic le ’s d riv e s y ste m .
—Allo w t h e e le ctric d riv e t o c o ol d ow n u n til t h e w arn in g l a m p g oes o ut.
—C heck t h e e n gin e c o ola n t l e ve l a t t h e co ola n t e xp an sio n t a n k (→ Coola n t).
If t h e e n gin e c o ola n t l e ve l is t o o l o w :
—Addin g c o ola n t (→ Coola n t)
If t h e w arn in g l a m p d oes n ot g o o ut, s e ek e xp ert a ssis ta n ce .
a n d d is p la y --.- i n t h e i n strum en t c lus te r
Th e in dic a to r l a m p f la sh es r e d .
Fau lt in t h e e n gin e c o olin g s y ste m .
—Sto p t h e v e h ic le a s s o on a s p ossib le a n d w hen s a fe t o d o s o .
—Se ek e xp ert a ssis ta n ce .
l ig hts up t o g eth er w it h
Th e in dic a to r l a m ps f la sh r e d .
Sto p t h e v e h ic le im med ia te ly
F au lt in t h e h ig h-v o lt a g e c o ola n t c ir c u it .
—D eactiv a te t h e v e h ic le ’s d riv e s y ste m .
—Se ek e xp ert a ssis ta n ce .
T ro ub le sho oting
Page 589 of 708

Fig . 1 I n t h e f ro n t c o m part m en t: c a p o f t h e b ra ke f lu id r e se rv o ir .
B ra ke f lu id w il l g ra d ually a b so rb w ate r f ro m t h e s u rro un din g a ir o ve r t h e c o urs e o f t im e. T h e b ra ke
sy ste m w il l b e d am ag ed if t h ere is t o o m uch w ate r in t h e b ra ke f lu id . T h e b oil in g p oin t o f t h e b ra ke
flu id is a ls o c o n sid era b ly r e d uce d b y t h e w ate r c o n te n t. H eavy u se o f t h e b ra ke s m ay c a u se a v a p our
lo ck in t h e b ra ke s y ste m if t h e w ate r c o n te n t is t o o h ig h. V ap our l o ck s r e d uce t h e b ra kin g e ffic ie n cy,
c o n sid era b ly in cre ase b ra kin g d is ta n ce a n d c a n e ve n c a u se t h e b ra ke s y ste m t o f a il c o m ple te ly . Y o ur
ow n s a fe ty a n d t h at o f o th er r o ad u se rs d ep en ds o n h avin g a b ra ke s y ste m t h at f u n ctio n s p ro p erly a t
a ll t im es → Bra ke f lu id.
B ra ke f lui d s p ecif ic a tio n
Volk sw ag en h as d eve lo p ed a b ra ke f lu id t h at h as b een o ptim is e d f o r t h e b ra ke s y ste m in t h e v e h ic le .
To e n su re t h e b est p ossib le o p era tio n o f t h e b ra ke s y ste m , V olk sw ag en e xp re ssly r e co m men ds t h e
use o f b ra ke f lu id c o m plia n t w it h V W s ta n dard 5 01 1 4.
B efo re u sin g a p art ic u la r b ra ke f lu id , c h eck t h at t h e s p ecif ic a tio n s p rin te d o n t h e c o n ta in er
co rre sp on d t o t h e v e h ic le r e q uir e m en ts .
B ra ke f lu id t h at is c o m plia n t w it h V W s ta n dard 5 01 1 4 is a va il a b le f ro m V olk sw ag en d eale rs h ip s.
If t h is b ra ke f lu id is n ot a va il a b le a n d it is n ece ssa ry t o u se a n oth er h ig h-q ualit y b ra ke f lu id in ste ad ,
bra ke f lu id t h at is c o m plia n t w it h D IN I S O 4 925 or U S s ta n dard FM VSS 1 16 D O T 4 C LA SS 6 c a n b e
use d .
B ra ke f lu id
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Not a ll b ra ke f lu id s t h at a re c o m plia n t w it h D IN I S O 4 925 o r U S s ta n dard FM VSS 1 16 D O T 4 C LA SS 6
h ave t h e s a m e c h em ic a l c o m posit io n . S o m e o f t h ese b ra ke f lu id s m ay c o n ta in c h em ic a ls t h at c a n
d am ag e o r d estro y b ra ke s y ste m c o m pon en ts o ve r t im e.
V olk sw ag en t h ere fo re r e co m men ds t h e u se o f b ra ke f lu id t h at is c o m plia n t w it h V W s ta n dard 5 01 1 4
to e n su re s u sta in ed o ptim al o p era tio n o f t h e b ra ke s y ste m .
Bra ke f lu id t h at is c o m plia n t w it h V W s ta n dard 5 01 1 4 f u lf il s t h e r e q uir e m en ts o f D IN I S O 4 925 o r U S
sta n dard FM VSS 1 16 D O T 4 C LA SS 6.
B ra ke f lui d l e ve l
Th e b ra ke f lu id l e ve l m ust a lw ays b e b etw een t h e M IN a n d M AX m ark in gs o n t h e b ra ke f lu id r e se rv o ir
a n d a b ove t h e M IN m ark in g → Bra ke f lu id.
T h e b ra ke f lu id l e ve l c a n not b e c h ecke d a cc u ra te ly in a ll m od els a s a f la p o r e n gin e c o m pon en ts m ay
p art ia lly c o n ce al t h e b ra ke f lu id c o n ta in er. I f t h e b ra ke f lu id l e ve l c a n not b e r e ad e xa ctly , p le ase g o t o
a q ualif ie d w ork sh op .
Th e b ra ke f lu id l e ve l d ro p s s lig htly d urin g v e h ic le o p era tio n a s t h e b ra ke p ad s w ear a n d t h e b ra ke s
are a u to m atic a lly a d ju ste d .
B ra ke f lui d l e ve l
Th e in dic a to r l a m p l ig hts u p r e d .
B ra ke f lu id l e ve l is t o o l o w .
— Do n ot d riv e o n !
—C heck t h e b ra ke f lu id l e ve l.
I f t h e b ra ke f lu id l e ve l is t o o l o w :
—In fo rm a q ualif ie d w ork sh op .
—H ave t h e b ra ke s y ste m c h ecke d .
C han g in g t h e b ra ke f lui d
Th e b ra ke f lu id s h ould b e c h an ged b y a q ualif ie d w ork sh op . V olk sw ag en r e co m men ds u sin g a
V olk sw ag en d eale rs h ip f o r t h is p urp ose . O nly b ra ke f lu id t h at c o n fo rm s w it h t h e r e q uir e d
sp ecif ic a tio n s h ould b e u se d .
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WAR N IN G
Bra ke f a il u re o r r e d uce d b ra kin g e ffic ie n cy c a n b e c a u se d b y t h e b ra ke f lu id l e ve l b ein g t o o l o w o r
by b ra ke f lu id t h at is t o o o ld o r u n su it a b le .
●T h e b ra ke s y ste m a n d b ra ke f lu id l e ve l m ust b e c h ecke d r e g ula rly .
●T h e b ra ke f lu id s h ould b e c h an ged r e g ula rly .
●H eavy u se o f t h e b ra ke s w it h o ld b ra ke f lu id c a n c a u se a v a p our l o ck . V ap our l o ck s r e d uce
b ra kin g e ffic ie n cy, c o n sid era b ly in cre ase b ra kin g d is ta n ce a n d c a n c a u se t h e b ra ke s y ste m t o f a il
c o m ple te ly .
●P le ase e n su re t h at t h e c o rre ct b ra ke f lu id is u se d . O nly u se b ra ke f lu id t h at is e xp lic it ly
c o m plia n t w it h V W s ta n dard 5 01 1 4.
●A ny o th er b ra ke f lu id o r a l o w -q ualit y f lu id c a n a ffe ct t h e f u n ctio n in g o f t h e b ra ke s a n d r e d uce
b ra kin g e ffic ie n cy.
●If a b ra ke f lu id c o m plia n t w it h V W s ta n dard 5 01 1 4 is n ot a va il a b le , u se a h ig h-q ualit y b ra ke
flu id c o m plia n t w it h D IN I S O 4 925 C LA SS 6 o r t h e U S s ta n dard F M VSS 1 16 D O T 4 , b ut o n ly in
e xce p tio n al c ir c u m sta n ce s.
●T h e r e fil le d b ra ke f lu id m ust b e n ew .
W AR N IN G
Bra ke f lu id is t o xic .
●In o rd er t o r e d uce t h e r is k o f p ois o n in g, n eve r u se b ottle s o r o th er c o n ta in ers t o s to re b ra ke
flu id . T h ere is a lw ays a r is k o f s o m eo n e d rin kin g f ro m s u ch c o n ta in ers , e ve n if t h ey a re l a b elle d
ap pro p ria te ly .
●B ra ke f lu id m ust a lw ays b e s to re d in it s o rig in al s e ale d c o n ta in er a n d k e p t o ut o f t h e r e ach o f
ch il d re n .
N OTIC E
B ra ke f lu id t h at h as l e ake d o r b een s p il t c a n d am ag e t h e v e h ic le p ain tw ork , p la stic p art s a n d t y re s.
W ip e o ff b ra ke f lu id t h at h as l e ake d o r b een s p il le d im med ia te ly f ro m a ll p art s o f t h e v e h ic le .
B ra ke f lu id c a n p ollu te t h e e n vir o n m en t. A ny s p il t s e rv ic e f lu id s m ust b e c le an ed u p a n d
d is p ose d o f p ro p erly .
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Th e 1 2-v o lt v e h ic le b atte ry is a c o m pon en t o f t h e e le ctric a l s y ste m a n d in e ve n t o f t h e h ig h-
vo lt a g e s y ste m f a il in g, s u p plie s t h e s a fe ty -re le va n t s y ste m s o f t h e v e h ic le w it h e n erg y. I n t h e
sc o p e o f m ain te n an ce w ork , t h e 1 2-v o lt v e h ic le b atte ry is c h ecke d a n d w here r e q uir e d , r e p la ce d .
Yo u s h ould o n ly c a rry o ut w ork o n t h e e le ctric a l s y ste m if y o u k n ow e xa ctly h ow t o p erfo rm t h e
re q uir e d t a sk s, a re a w are o f t h e g en era l s a fe ty p ro ce d ure s a n d h ave a cce ss t o t h e c o rre ct
e q uip m en t, s e rv ic e f lu id s a n d s u it a b le t o ols . F ail in g t o c a rry o ut w ork c o rre ctly c a n c a u se s e rio us
in ju rie s . A ll w ork s h ould b e c a rrie d o ut b y a q ualif ie d w ork sh op . V olk sw ag en r e co m men ds u sin g
a V olk sw ag en d eale rs h ip f o r t h is p urp ose .
In fo rm atio n o n w arn in g a n d in dic a to r l a m ps t h at l ig ht u p c a n b e f o un d in t h e t ro ub le sh ootin g
se ctio n s a t t h e e n d o f t h e c h ap te r (→ 12-v o lt v e h ic le b atte ry).
L o ca tio n o f 1 2-v o lt v e h ic le b atte ry
T h e 1 2-v o lt v e h ic le b atte ry is l o ca te d in t h e f ro n t c o m part m en t.
E xp la n atio n o f t h e w arn in g s o n t h e 1 2-v o lt v e h ic le b atte ry
A lw ays w ear e ye p ro te ctio n !
E le ctro ly te is v e ry c o rro siv e a n d c a u stic . A lw ays w ear p ro te ctiv e
g lo ve s a n d e ye p ro te ctio n !
N o f ir e , s p ark s, n ake d l ig hts o r s m okin g!
A h ig hly e xp lo siv e m ix tu re o f g ase s is g iv e n o ff w hen t h e 1 2-v o lt
v e h ic le b atte ry is c h arg in g!
A lw ays k e ep c h il d re n a w ay f ro m e le ctro ly te a n d t h e 1 2-v o lt v e h ic le
b atte ry !
A lw ays o b se rv e t h e o w ner's m an ual!
1 2-v o lt v e hi cle b atte ry
Int ro d uctio n to t he t o p ic