Draining and filling coolant system: VW 1.6 (AYD, BBW, BFS)

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

T10007 Refractometer
V.A.G1274/8 Adapter
V.A.G 1306 Drip tray
VAS 5024 Assembly tool for spring-type clips

Not illustratd:

VAS 6096 Coolant system chargig unit

Draining

Warning:
Steam can be released when removing the cap from the expansion tank, cover cap with a cloth and open carefully.
Open cap on coolant expansion tank.
Remove sound insulation:

=> General body repairs, exterior; Repair group 50; Noise insulation (petrol engine) - Assembly overview
General body repairs, exterior
Noise insulation (petrol engine) - Assembly overview

To drain coolant from radiator remove drain plug -arrow-.

To drain coolant from engine also remove coolant hose from oil cooler -arrow-.

Note:

Observe waste disposal regulations!

Filling

Notes:

Only use coolant additive G 12 in accordance with TL VW 774 F.
Distinguishing features: colour lilac
G 12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with frost and corrosion protection additives.
G 12 lilac (according to TL VW 774 F) can be mixed with coolant additive G12 red.
Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).

The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40 %.
If for climatic reasons a higher frost protection is required, the amount of G 12 can be increased, but only up to 60 % (frost protection to about -40 °C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.

Refractometer T10007 is recommended to determine coolant freezing temperature.
If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended mixture ratios:

Anti-freeze / to · Anti-freeze proportion · G 121) · Water1)
-25 °C / -35 °C · 40 % / 50 % · 2.0 ltr. / 2.5 ltr. · 3.0 ltr. / 2.5 ltr.

1)
The quantity of coolant can vary in dependence on the vehicle equipment.

Work sequence

Screw drain plug into radiator and secure coolant hose on oil cooler connection.

Not using coolant system charging unit VAS 6096

Fill coolant slowly up to upper hatched field mark-Arrow- on expansion tank.

Using coolant system charging unit VAS 6096

Screw adapter V.A.G1274/8 onto expansion tank.
Filling coolant system using coolant systm charging unit VAS 6096:

=> Refer to instruction manual for coolant system charging unit VAS 6096

With and without coolant system charging unit VAS 6096

Seal expanson tank.
Switch off heater and air conditioner.
Start engine and maintain an engine speed of about 2000 rpm for approx. 3 minutes.

Run engine until radiator fan starts.
Switch off ignition.

Warning:
Steam can be released when removing the cap from the expansion tank, cover cap with a cloth and open carefully.
Check coolant level and replenish coolant if necessary:

The coolant level must be at the upper hatched field mark, when the engine is at operating temperature-arrow-.
When the engine is cold the coolant level should be around the middle of the hatched field.