Coolant drain
Open the hood and remove the cap from the expansion tank.
Safety instructions. When opening the expansion tank cap on a hot engine, care must be taken, as escaping vapors can cause severe burns. To do this, close the cap of the expansion tank with a thick layer of cloth and slowly unscrew the cap until a hissing sound is heard. After the hiss stops, slowly unscrew and remove the cap from the expansion tank. Remove the cap from the expansion tank only at temperatures below +90°C.
Raise the front of the car and secure it on stands. Remove the lower mudguard of the engine compartment.
Place a clean container under the radiator to catch any escaping coolant.
Petrol engines.Disconnect the bottom hose from the radiator. To do this, remove the locking bracket (see fig. 3.3) on the side of the coupler, then disconnect the hose. Collect the coolant in a prepared container.
Engine 1.8-I / 125 hpAdditionally, disconnect the cooling system hose from the oil heat exchanger, for which loosen the clamp and remove the hose from the heat exchanger (see fig. 3.4). The oil heat exchanger is located at the base of the oil filter. Collect the coolant in a prepared container.
Engine 1.8-I / 150 hp Unscrew the coolant drain plug located on the water pump and drain the coolant from the engine block (see fig. 3.5). Collect the coolant in a prepared container.
Engine 1.9-I-TDI. Using a coin or wide blade screwdriver, unscrew the coolant drain plug from the radiator (see fig. 3.6). Collect the coolant in a prepared container.
To drain the coolant more completely, remove the thermostat.
V6 2.4-/2.8-I petrol engines.Using a hex wrench, unscrew the drain plug on the engine block (see fig. 3.7). The plug is located at the bottom left side, near the gearbox flange.
Engine V6-2,5-I-TDI.Remove the spring retainer 1 that secures the temperature sensor to the cooling system hose at the bottom right of the engine. Remove the temperature sensor. Drain the engine coolant by unscrewing drain plug 2 (pic. 3.8).
On the left side of the engine, disconnect the cooling system hose from the oil heat exchanger, to do this, use special pliers, for example, HA2ET 798-5, loosen clamp 1 and remove the hose (pic. 3.9). Hoses 2 and 3 (pic. 3.9) don't shoot.
Filling the cooling system
If the coolant is heavily contaminated, flush the cooling system. Since the coolant cannot be completely drained from the cooling system, it is recommended to flush the cooling system each time the coolant is drained.
Prepare the required amount of coolant from 50% water and 50% antifreeze with anti-corrosion additive «G12 AD8».
Gas engine.Connect the lower coolant hose to the radiator and secure the coupler with the retaining clip.
Engine 1.9-I-TDI.Screw the coolant drain plug into the radiator and tighten to 10 Nm. Install thermostat.
Engines 1.8-I/125 hp and V6-2.5-I-TDI.Connect the coolant hose to the oil heat exchanger and secure with a hose clamp.
Engine V6-2,5-I-TDI.Install the temperature sensor on the cooling system hose in the lower right part of the engine and secure it with a spring clip 1 (pic. 3.8). Screw drain plug 2 into the engine block.
Engine 1.8-I / 150 hpScrew the coolant drain plug into the water pump and tighten to 30 Nm.
Petrol engines V6 2.4-/2.8-I.Screw the screw plug with a new O-ring into the engine block and tighten to 20 Nm.
Install the lower engine mudguard and lower the vehicle to the ground.
Move the temperature control of the heating system to the maximum temperature position.
Engine 1.8-I.Near the bulkhead of the engine compartment, loosen the clamp of the coolant return hose from the heater radiator and slide the hose from the fitting so that the fitting does not block the hole in the air bleed hose (see fig. 3.10).
Petrol engines V6 2.4-/2.8-I. The bleed screw is located on the front side in the middle pipe of the cooling system, in the area between the servo pump and the left cylinder head (see fig. 3.11).
Engine V6-2,5-I-TDI.On the front side of the partition of the engine compartment, unscrew the air bleed fittings located at the connection point of the heater radiator hoses by two turns (see fig. 3.12).
Instead of the expansion tank cap, screw in the threaded adapter VAG 1274/9 with a tube 42 mm in diameter and 100 mm high (see fig. 3.13). This is necessary in order to completely fill the engine cooling system with coolant and remove air from it. In the absence of a special device, you can make it yourself. It is also possible to unscrew the expansion tank from the bracket and raise it, together with the connected hoses, by 10 cm and fix it in this position.
Engines 1.8-I.Pour coolant into the cooling system until coolant flows out of the hole in the coolant return hose from the heater. Put the hose on the fitting until it stops and secure it with a clamp.
Petrol engines V6 2.4-/2.8-I. Fill the coolant into the expansion tank until coolant flows out through the bleed screw in the middle pipe of the cooling system. Tighten the screw to 20 Nm.
Engine V6-2,5-I-TDI. Fill the coolant into the expansion tank until the coolant flows out through the air bleed fittings located at the connection point of the heater radiator hoses. To improve air removal, pinch the thicker hose several times by hand. Screw in the bleeder fittings.
If the expansion tank was removed from the bracket, install it on the bracket. Remove the tool that was installed instead of the cap from the expansion tank and screw the cap onto the expansion tank.
Start the engine and let it run for 3 minutes at 2000 rpm.
Run the engine to idle until the lower radiator hose is warm, then turn off the engine.
Check the coolant level and top up if necessary.
On a hot engine, the coolant level should be at the MAX mark, and on a cold engine, it should be between the MAX and MIN·marks.
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