Volkswagen New Beetle. Manual - part 901

1. 15 N.m  

2. Toothed belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING .  

3. Coolant pump 

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Check for ease of movement  

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If damaged or leaking replace complete  

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Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING  

4. O-ring 

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Replace  

5. Coolant thermostat 

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Checking: heat-up thermostat in water  

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Opening commences approx. 87 °C  

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Ends approx. 102 °C  

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Opening lift min. 7 mm  

6. O-ring 

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Replace  

7. Connection  

8. Hose to heat exchanger 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

9. Connector 

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4 pin  

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Up to MY 1999: Wiring chamber 1 and wiring chamber 3 for -G62-  

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From MY 2000: Wiring chamber 3 and wiring chamber 4 for -G62-  

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Gold plated terminals  

10. Engine Coolant Temperature (ECT) sensor -G62- 

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With ECT sensor -G2-  

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For Engine Control Module  

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If necessary, release pressure in cooling system before removing  

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Checking: 

See Engine Coolant Temperature (ECT) Sensor, Checking

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

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Checking and erasing DTC memory: 

See Diagnostic Trouble Code (DTC) memory, checking and erasing 

11. O-ring 

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Replace  

12. Retaining clip 

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Check seated securely  

13. Connection  

14. Upper coolant hose of radiator 

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Secured to radiator with retaining clip  

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Check securely seated  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

15. Lower coolant hose 

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Secured to radiator with retaining clip  

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Check securely seated  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

16. Upper coolant pipe 

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Secured to intake manifold  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

17. Cap 

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Check with cooling system tester VAG 1274 and adapter VAG 1274/9  

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Test pressure 1.4 to 1.6 bar  

18. O-ring 

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Replace if damaged  

19. Expansion tank 

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Perform leak test of cooling system with cooling system tester VAG 1274 and adapter VAG 1274/8 

20. 10 N.m  

21. Coolant pipe 

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Secured to oil filter bracket  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

22. Oil cooler 

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Removing and installing. See PART II , item 22  

23. 15 N.m  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

Fig. 2: Identifying Cooling System Components - Engine Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTION DIAGRAM 

Only vehicles with engine code APH 

Vehicles with engine codes AWP, AWV: See Vehicles with engine codes: AWP (only manual transmission), 
AWV (manual and automatic transmission) . 

1. Expansion tank  

2. Turbocharger  

3. Intake manifold  

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

4. Cylinder head/cylinder block  

5. Heating system heat exchanger  

6. Coolant pipe  

7. ATF cooler 

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Only on vehicles with automatic transmission  

8. Oil cooler  

9. Upper coolant hose  

10. Cooler  

11. Lower coolant hose  

12. After-run coolant pump -V51-  

13. Coolant pump/coolant thermostat  

Fig. 3: Coolant Hose Connection Diagram - Engine Code APH

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)