Volkswagen Golf Variant / Jetta. Manual - part 407

 

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Volkswagen Golf Variant / Jetta. Manual - part 407

 

 

the coolant hose at the oil cooler -arrow-.

Filling:

Caution

Only use distilled water for mixing with G12 plus plus. Using

distilled water provides optimum corrosion protection.

Note

Only use coolant additive G 12 Plus Plus that conforms to TL

VW774 G.

Use distilled water for mixing.

G12 plus-plus prevents freeze and corrosion damage and

scaling and it increases the boiling temperature. For this rea‐

son the cooling system must be filled all year round with

coolant and corrosion protection additives.

Because of its high boiling point, the coolant contributes to

engine reliability under heavy engine loads, particularly in

countries with tropical climates.

Freeze protection should be guaranteed to about -25 ℃ (-13

°F) (in countries with arctic climates: to about -35 ℃ (-31 °F)).

The coolant concentration must not be reduced by adding wa‐

ter even in warmer seasons and in warmer countries. The

coolant additive portion must be at least 40%.

If a stronger freeze protection is required, the G12 plus-plus

ratio can be increased.

But only up to 60% (freeze protection down to approximately

-40 °C (-40 °F)). Otherwise the freeze protection is lessened

and the cooling effect will be diminished.

Do not use the old coolant again if replacing the radiator, heat‐

er core, cylinder head or cylinder head gasket.

The Refractometer - T10007- is recommended for determining

the current freeze protection density.

Recommended Mixture Ratios:

Frost Protection

to

Freeze Protection Por‐

tion

-G 12 plus-plus- . Refer to

3)

.

Distilled Water. Refer to 

3)

 

,

-25 °C (-13 °F)

40 %

3.2 liters (3.38 quarts)

4.8 liters (5.07 quarts)

-35 °C (-31 °F)

50 %

4.0 liters (4.22 quarts)

4.0 liters (4.22 quarts)

3) The coolant quantity can vary depending upon the vehicle equipment.

1. Cooling System Components    

211

-arrow-.

50 ; Noise Insulation .

With Cooling System Charge Kit - VAS6096- :
– Install the Cooling System Tester - Adapter - VAG1274/8- in

the coolant expansion tank.

– Fill the coolant circuit using Cooling System Charge Kit -

VAS6096- . Refer to Operating Instructions for Cooling Sys‐

tem Charge Kit VAS6096.

Without Cooling System Charge Kit - VAS6096- :

– Slowly fill the coolant up to the upper marking in the hatched

area on the expansion tank.

– Seal the coolant expansion tank.
– Start the engine and keep the engine speed at about 2000

RPM for approximately three minutes.

– Let the engine run in idle until the Radiator Fan - V7- switches

on.

DANGER!

Risk of scalding due to hot steam and hot coolant:

♦ The cooling system is under pressure when the engine is

warm.

♦ Wear protective eyewear and protective clothing to pre‐

vent eye injury and scalding.

♦ Reduce the pressure by covering the coolant reservoir cap

with a cloth and carefully opening.

– Check the coolant level and fill if necessary.
• When engine is warm, coolant level must be at top marking

and when the engine is cold, it must be in the middle of the

hatched field.

1.10

Cooling System, Checking for Leaks

⇒ “1.10.1 Pressure Checking”, page 212
⇒ “1.10.2 Pressure Relief Valve in Cap, Checking”, page 214

 .

1.10.1

Pressure Checking

Special tools and workshop equipment required

212

DANGER!

Risk of scalding due to hot steam and hot coolant:

♦ The cooling system is under pressure when the engine is

warm.

♦ Wear protective eyewear and protective clothing to pre‐

vent eye injury and scalding.

♦ Reduce the pressure by covering the coolant reservoir cap

with a cloth and carefully opening.

– Open the cap on the coolant expansion tank.
– Install the Cooling System Tester - Adapter - VAG1274/8- in

the coolant expansion tank.

– Clamp the Adapter - VAG1274B/1- in the Cooling System

Tester - Adapter - VAG1274/8- .

– Connect the Adapter - VAG1274B/1- to the Cooling System

Tester - VAG1274B- using the connecting hose provided.

– Generate approximately 1 bar (14.5 psi) pressure using the

cooling system tester hand pump.

DANGER!

Risk of scalding due to hot steam and hot coolant:

♦ The existing pressure must be reduced before discon‐

necting the Cooling System Tester - VAG1274B- from the

connecting hose or the Adapter - VAG1274B/1- .

♦ To do this, press the pressure release valve on the Cooling

System Tester - VAG1274B- until the pressure gauge dis‐

plays the value »0«.

If the pressure drops:
– Look for leaks and correct.

1. Cooling System Components    

213

Pressure Relief Valve in Cap, Checking

DANGER!

Risk of scalding due to hot steam and hot coolant:

♦ The cooling system is under pressure when the engine is

warm.

♦ Wear protective eyewear and protective clothing to pre‐

vent eye injury and scalding.

♦ Reduce the pressure by covering the coolant reservoir cap

with a cloth and carefully opening.

– Open the cap on the coolant expansion tank.
– Install the cap in the Cooling System Tester - Adapter -

VAG1274/9- .

– Clamp the Adapter - VAG1274B/1- in the Cooling System

Tester - Adapter - VAG1274/9- .

– Connect the Adapter - VAG1274B/1- to the Cooling System

Tester - VAG1274B- using the connecting hose provided.

– Generate a maximum pressure of 1.6 bar (23.2 psi) using the

hand pump on the Cooling System Tester - VAG1274B- .

• Pressure relief valve must not open yet.
If pressure relief valve opens prematurely:
– Replace the cap.
– Increase the pressure to above 1.6 bar (23.2 psi).
• Pressure relief valve must open.
If the pressure relief valve does not open:
– Replace the cap.

1.11

Oil Cooler, Checking for Leaks

Special tools and workshop equipment required
♦ Refractometer - T10007A-
♦ Hose Clamps - Up To 25 mm - 3094-
♦ Cooling System Tester - VAG1274B-
♦ Cooling System Tester - Adapter - VAG1274/8-
♦ Hose Clip Pliers - VAS6362-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Expansion Tank - 1K0 121 407 A or 6Q0 121 407 A or 1J0 121

407 B-

♦ Plug - 191 211 343-
♦ Closure Cap - 1J0 121 324-
♦ Coolant Hose - 251 265 056-
Test Conditions
• Engine must be cold.

214

 

 

 

 

 

 

 

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