2.0L - Cooling System - Engine Code(s): Cjaa: Maintenance Volkswagen Golf Mk7

DRAINING AND FILLING

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip Tray for VAS 6100 VAS 6208
3. Hose Clip Pliers VAS 6340
4. Cooling System Charge Unit VAS 6096
5. Adapter V.A.G 1274/8

Draining

Open the coolant expansion tank cap.

Remove the noise insulation. Refer to Description and Operation

Remove the coolant hoses -1- from the engine coolant circulation pump 2 -V178- -2-.

Scheme 3

Remove the coolant hose clip -arrow- downward and remove the coolant hose from the radiator quick-release coupling.

Scheme 4

In addition, to drain the coolant from the engine, disconnect the coolant hose -arrow- from the oil cooler.

Scheme 5

Note. Observe disposal regulations!

Filling

Note. The water portion of the coolant influences the effectiveness of the coolant. Volkswagen has decided to define the water quality used in the cooling system based on the different mixtures and country and regional requirements. Use distilled water. For this reason, we recommend using distilled water for older models when adding coolant or filling coolant for the first time. On newer models (from MY 10), distilled water is required.

Note. Only use coolant additive G 12 plus-plus that conforms to TL VW 774 G. Use distilled water only. G 12 plus-plus prevents frost and corrosion damage, scaling and also raises the boiling point. The cooling system must be filled with coolant additive year-round. 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 down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -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%. The amount of G12 plus-plus can be increased if more freeze protection is needed. However, it may only be increased up to 60%, which provides freeze protection down to approximately -40 °C (-40 °F). Otherwise the freeze protection and cooling effect are reduced. If the radiator, heater core, cylinder head or cylinder head gasket is replaced, do not reuse old coolant. The refractometer T10007 is recommended for determining freeze protection density.

Recommended Mixture Ratios (use only distilled water for mixing)

Install the lower coolant hose and secure with the clip -arrow-.

Connect the coolant hoses to the oil cooler and to the engine coolant circulation pump 2.

Install the noise insulation. Refer to Description and Operation

Filling with the Cooling System Charge Unit VAS 6096

Install the adapter V.A.G 1274/8 onto the expansion tank.

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

Filling without the Cooling System Charge Unit VAS 6096

Slowly fill the coolant up to the upper mark in the hatched area on the expansion tank.

Scheme 6

Install the expansion tank cap.

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

Let the engine run at idle until the coolant fan turns on.

Check the coolant level and fill if necessary. With the engine at operating temperature, the coolant level must be at the top mark, with a engine cold, it must be in the center of the hatched area.

Scheme 7

1. Coolant Expansion Tank With a sealing cap. Pressure relief valve in cap, checking. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-480924-S42353293712012061900000) .
2. Cylinder Head and Cylinder Block Change the coolant after replacing.
3. Cooler for Exhaust Gas Recirculation (EGR) Change coolant after replacing. Removing and installing, refer to «EXHAUST GAS RECIRCULATION SYSTEM COMPONENTS OVERVIEW»(ref-480915-S39763402542012061900000) .
4. Auxiliary Heater Not available in the US/Canadian market.
5. Recirculation Pump -V55
6. Heater Core Change the coolant after replacing.
7. Transmission Oil Cooler For the Direct Shift Gearbox (DSG). Change coolant after replacing.
8. Engine Oil Cooler
9. Engine Pre-Warmer Not available in the US/Canadian market.
10. Radiator Change the coolant after replacing.
11. 4/2-Way Valve with Thermostat Removing and installing, refer to «4/2-WAY VALVE WITH THERMOSTAT»(ref-480924-S30384473772012061900000) .
12. Coolant Pump

Scheme 8

1. Radiator Removing and installing, refer to «RADIATOR»(ref-480924-S23402037952012061900000) . After replacing, replace the entire amount of coolant.
2. O-ring Replace if damaged.
3. Upper Coolant Hose Coolant hose connection diagram. Refer to «COOLANT HOSE CONNECTION DIAGRAM»(ref-480924-S33593852222012061900000) .
4. Cap Check using the cooling system tester V.A.G 1274 and adapter V.A.G 1274/9. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-480924-S42353293712012061900000) .
5. Connector
6. Bolt 5 Nm
7. Expansion Tank Perform a cooling system leak test using the cooling system tester V.A.G 1274 and adapter V.A.G 1274/8. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-480924-S42353293712012061900000) .
8. Lower Coolant Hose Coolant hose connection diagram. Refer to «COOLANT HOSE CONNECTION DIAGRAM»(ref-480924-S33593852222012061900000) .
9. Nut 5 Nm
10. Bolt 5 Nm
11. Coolant Fan -V7
12. Right Coolant Fan -V35
13. Connector
14. Fan Shroud Removing and installing, refer to «FAN SHROUD AND FANS»(ref-480924-S16002511532012061900000) .