Note: A description of checking and adjusting the coolant level, as well as some checks of the cooling system, are given in Sections 4 and 5 Chapter 1. The type of coolant is indicated in Specifications for Chapter 1. The following describes the replacement of the coolant.
Petrol models 1.4 l
Note: On 1.4 liter engines, depending on the repair work being carried out, it may be sufficient to drain the coolant either only from the engine cooling system radiator circuit, or only from the intercooler radiator, although these radiators are combined into a non-separable unit. When replacing the coolant, it must be drained from both radiators.
1. Open the cap of the expansion tank and remove the soundproofing under the engine compartment (see chapter 11).
2. Drain the coolant from the radiator of the engine cooling system. To do this, loosen the clamp (see resist. illustration) and disconnect the coolant hose from the lower radiator connection.
2.2 Radiator bottom connection
3. Drain the coolant from the intercooler radiator by disconnecting the coolant hose from its lower pipe (see resist. illustration).
2.3 Lower intercooler radiator connection
4. Connect the hoses, install the sound insulation and fill the coolant as described below.
5. Turn off the climate system, slowly fill the expansion tank to the mark "MAX" and close it with a lid.
6. Connect the diagnostic tool VAS5051 (see chapter 5) and do the function "filling and bleeding the cooling system".
7. Check and, if necessary, correct the coolant level (see Section 4 of Chapter 1).
Petrol models 1.8 and 2.0 l
8. Open the cover of the expansion tank.
9. Remove the sound insulation under the engine compartment (see chapter 11).
10. Loosen clamps (1 and 2 on resist. illustrations) and remove the pressure air hose.
2.10 Pressure air hose
11. Loosen clamp (see illustration 2.2) and disconnect the coolant hose from the lower radiator connection. Collect the escaping coolant.
12. Remove from circulation pump "V51" lower coolant hose (left arrow in Illustration 23.26 of Chapter 2). Collect the escaping coolant.
13. On models with an additional heater, disconnect the hoses (arrows in Illustration 30.10 of Chapter 2) and collect coolant.
14. Connect the hoses, install the sound insulation and fill the coolant as described below.
15. Turn off the climate system, slowly fill the expansion tank to the mark "MAX" and close it with a lid.
16. Start the engine and let it run for about 3 minutes at 2000 rpm, and then wait until the radiator fan turns on.
17. Check and, if necessary, correct the coolant level (see Section 4 of Chapter 1).
Petrol models 3.6 l
18. Open the cover of the expansion tank and remove the soundproofing under the engine compartment (see chapter 11).
19. Loosen clamp (see illustration 2.2) and disconnect the coolant hose from the lower radiator connection. Collect the escaping coolant.
20. On models with an additional heater, disconnect the coolant hoses from its pipes and collect the flowing coolant.
21. Connect the hoses, install the soundproofing and fill the coolant using the VAG1274/8 tool installed on the expansion tank cap.
Diesel models (motors CFFB, CFGB, CLJA)
22. Open the expansion tank and remove the sound insulation under the engine compartment (see chapter 11).
23. Loosen the clamp (2 to resist. illustrations) and remove the pressure air hose. Plug the hole in the intercooler.
2.23 Pressure air hose clamps
24. Remove the right coolant hose from the radiator by pulling out the retainer (see resist. illustration), and collect the escaping coolant.
2.24 Right coolant hose
25. Disconnect coolant hoses (3 in Illustration 34.15 of Chapter 2) from coolant circulation pump No. 2 "V178".
26. Disconnect the coolant hose from the oil cooler (see resist. illustration) and collect the resulting coolant.
2.26 Coolant hose for oil coolers
27. Connect the disconnected coolant hoses using new seals. Install soundproofing and fill coolant as described below.
28. Turn off the climate system, slowly fill the expansion tank to the mark "MAX".
29. Start the engine and let it run for about 2 minutes at 1500 rpm, constantly adjusting the coolant level.
30. Close the expansion tank and wait for the fan to turn on "V7" radiator.
31. Check and, if necessary, correct the coolant level (see Section 4 of Chapter 1).