Volkswagen New Beetle. Manual - part 1996

Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 28: Vacuum Diagram Intake Manifold, Upper Section (4.0L W8) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Vacuum Diagrams

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:50:55 AM

Page 28 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 29: Vacuum Diagrams Secondary Air Injection System (4.0L W8) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Vacuum Diagrams

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:50:55 AM

Page 29 

© 2004 Mitchell Repair Information Company, LLC. 

1998-2004 HVAC

Air Conditioning - New Beetle 

A/C REFRIGERANT SYSTEM 

SAFETY MEASURES 

The subassemblies and lines of the air conditioner are filled with Tetrafluoroethane also known as refrigerant R-
134a. 

A label on the lock carrier in the engine compartment indicates the refrigerant type and capacity. 

WARNING:

z

Always use an Underwriter's Laboratory (UL) approved refrigerant 
recovery/recycling/recharging unit such as Kent-Moore ACR

4

 , or 

equivalent, whenever discharging an R-134a A/C system.  

z

As of January, 1992 any person who services a motor vehicle air 
conditioner MUST, by law, be properly trained and certified and use 
approved refrigerant recycling equipment. Technicians must 
complete an EPA approved recycling course to be certified.  

z

State and Provincial governments may have additional requirements 
regarding air conditioning servicing. Always comply with local laws. 

WARNING:

A/C system is filled with refrigerant gas which is under pressure. Always 
be careful that refrigerant does not come in contact with your skin. If 
liquid refrigerant has come in contact with your skin or eyes: 

z

Do not rub skin or eyes  

z

Immediately flush with cool water for 15 minutes  

z

Rush to a doctor or hospital  

z

Do not attempt to treat yourself  

z

Work in a well ventilated area because refrigerant gases are heavier 
than air, displace oxygen and may cause suffocation in areas of 
poor air circulation, like under the car.  

z

Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose 
and throat. Always wear hand and eye protection (gloves and 
goggles) when working around the A/C system. Keep refrigerant 
containers stored below 50 °C (122 °F) and never drop from high 
places. DO NOT warm refrigerant containers with an open flame. If 
refrigerant needs to be warmed, place bottom of tank in warm water. 

z

Keep refrigerant away from open flames because poisonous gas will 
be produced if it burns. Do not smoke when refrigerant gases are 
present for the same reason.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

WARNING:

z

Electric welding near refrigerant hoses causes R-134a to decompose 
from ultraviolet light. Discharge system before electric welding.  

z

Pressurized R-134a refrigerant in the presence of oxygen may form a 
combustible mixture. Never introduce compressed air into any R-
134a container (full or empty), A/C component or piece of service 
equipment  

z

Do not expose any component of the A/C system to high 
temperatures (for example, open flames). Excessive heat will cause 
a pressure increase which could burst the system.  

z

Do not steam clean condensers or evaporators. Use only cold water 
or compressed air.  

CAUTION:

z

Before working on electrical system, obtain radio security code and 
disconnect battery Ground (GND) strap.  

z

When reconnecting battery, always check operation of vehicle 
equipment such as radio, clock, and power windows according to 
Repair Manual and/or Owner's Manual.  

z

R-12 and R-134a refrigerant are NOT compatible. Never add R-12 
refrigerant to an R-134a system or R-134a refrigerant to an R-12 
system. If the refrigerants are mixed, total system contamination will 
occur and compressor failure may result.  

z

Refrigerant oils used for the R-134a system and R-12 system are NOT 
compatible. Use only the specified synthetic oil (Polyalkylene 
Glycol/PAG) for the R-134a refrigerant system. DO NOT use R-12 
system oil in an R-134a system or R-134a system oil in an R-12 
system. If the refrigerant oils are mixed, system contamination will 
occur and compressor failure may result.  

z

R-134a refrigerant system oil (PAG oil) absorbs moisture very 
rapidly. Moisture combines with the refrigerant to form acids which 
will damage the system. Use only the specified oil from a sealed 
container and ALWAYS reseal oil container immediately after use. 
DO NOT use oil if it has become contaminated with moisture.  

CAUTION:

z

Immediately plug open connections on A/C components to prevent 
dirt and moisture contamination. Likewise, DO NOT remove new 
components from packaging until ready to install. Immediately 
tighten component connections after installation.  

z

Always use separate refrigerant recovery/recycling/recharging 
servicing equipment for R-12 and R-134a systems. DO NOT use one 
piece of equipment for both R-12 and R-134a systems. The residual 
traces of refrigerant will contaminate and damage the equipment. 
Servicing equipment includes recovery/recycling/recharging unit, 
charging station, vacuum pump, manifold gauges, etc.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle