Refilling Cooling System - Gasoline (Water-Cooled)

1. Set heater controls to maximum heating position.
2. Open control valve for auxiliary heater under rear seat.
3. Remove radiator grille.
4. Raise vehicle approx. 15 3/4" (40cm) at front under the cross-member with floor jack and wooden support.
5. Open breather valve on radiator. See Fig 1 .
6. Open breather valve in engine compartment. See Fig 1 .
7. Fill cooling system via expansion tank until tank is filled to the brim and remains full.
8. Run engine @2000 rpm, top up tank until coolant flows at radiator breather valve with NO air bubbles.
9. Add coolant until tank is full and close tank with cap.
10. Turn off ignition & restart engine after about 20 seconds.
11. At about 2000 rpm oen cap of expansion tank.
12. Close radiator breather valve when coolant flows out. See Fig 1 .
13. Add coolant until tank is full and close tank with cap.
14. Close breather valve in engine compartment. See Fig 1 .
15. Turn off engine.
16. Check coolant level in expansion tank and top up.
17. Close expansion tank with cap.

Fig 1: Cooling System (Gasoline Shown - Diesel Similar)

Courtesy of VOLKSWAGEN UNITED STATES, INC.