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2.5L - Cooling System - Engine Code(s): Bpr & Bps (Hatchback): Maintenance Volkswagen Beetle A4 facelift

Cooling Fan 3 illustrations ~645 words

DRAINING AND FILLING

Special tools and workshop equipment required

  1. Refractometer T10007
  2. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
  3. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
  4. Cooling system charge unit VAS 6096
  5. Adapter VAG 1274/8

Draining

Note. Drained coolant must be stored in a clean container for disposal or reuse. Follow disposal regulations.

WARNINGHot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.

Open the coolant expansion tank cap.

Remove the noise insulation. Refer to Description and Operation .

Place the VAG 1306 or VAS 6208 underneath.

Loosen the drain plug -arrow- to drain the coolant from radiator.

Scheme 1

Scheme 1
Scheme 1

Filling

CAUTIONOnly mix with clean tap water. Well water does not have the quality needed to ensure the coolant will function correctly.

Note. On vehicles from Model Year (MY) 2008, only use coolant additive G12 plus-plus that conforms to "TL VW 774 G". On vehicles through MY 2007, coolant additive G12 plus that conforms to "TL VW 774 F" and G12 plus-plus that conforms to "TL VW 774 G" can be used. G12 plus-plus may be mixed with the previous coolant additive G12 plus. Both are colored purple. Coolant additives marked with "Conforms to TL VW 774 G" or "Conforms to TL VW 774 F" prevent freezing and corrosion damage and scaling and they increase the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. 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 (-13 °F) (in arctic climatic countries to about -35 °C (-31 °F)). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If for climatic reasons a greater frost protection is required, the amount of coolant additive of can be increased, but only up to 60% (frost protection to about -40 °C (-40 °F), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. Refractometer T10007 is recommended for determining freeze protection density. If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended Mixture Ratios

Frost protection toAntifreeze amountG 12 plus (1) G 12 plus-plus (1)Water (1) , (2)
25 °C (-13 °F) -35 °C (-31 °F)40% 50%3.6 liters 4.5 liters5.4 liters 4.5 liters
(1) The quantity of coolant can vary depending upon the vehicle equipment. (2) Only use clean tap water.
(1)The quantity of coolant can vary depending upon the vehicle equipment.
(2)Only use clean tap water.

Tighten the drain plug in radiator -arrow-.

Install the noise insulation. Refer to Description and Operation .

Fill using VAS 6096.

Install the VAG 1274/8 onto the expansion tank.

Fill the coolant circuit using the VAS 6096. Refer to the operating instructions for cooling system filler unit VAS 6096.

Filling without VAS 6096

Slowly fill the coolant up to the top mark of the hatched area -arrow- on the expansion tank.

Scheme 2

Scheme 2
Scheme 2

Install the expansion tank cap.

Turn off the heater and Air Conditioning (A/C).

Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.

Let the engine run until the fan starts up.

WARNINGHot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.

Check the coolant level and top off as necessary.

  1. With the engine at operating temperature, coolant level must lie at the top marking of the hatched area -arrow-.
  2. With the engine cold, the coolant level should be located approximately in the center of the hatched area.

Scheme 3

Scheme 3: COOLANT HOSE CONNECTION DIAGRAM
Scheme 3: COOLANT HOSE CONNECTION DIAGRAM
  1. Radiator Removal and installation, refer to «RADIATOR»(ref-492747-S38874411092012080600000) . Replace the coolant after replacing.
  2. Oil Cooler
  3. Coolant Pump and Coolant Thermostat Coolant pump removal and installation, refer to «COOLANT PUMP»(ref-492747-S09199616202012080600000) . Thermostat removal and installation, refer to «COOLANT THERMOSTAT»(ref-492747-S01615363012012080600000) . Checking coolant thermostat -item 16- «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(ref-492747-S38423324582012080600000) .
  4. Cylinder Head/Cylinder Block Replace the coolant after replacing.
  5. Expansion Tank With the sealing cap Checking pressure relief valve in cap. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-492747-S24622964152012080600000) .
  6. Intake Manifold
  7. Throttle Valve Control Module -J338- Connection only for coolant heated throttle valve control module.
  8. Quick Release Coupling
  9. Heater Core Replace coolant after replacing.
  10. Transmission Oil Cooler Only for vehicles with a automatic transmission.
  11. Coolant Line
  12. Coolant Distribution Housing

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