Volkswagen New Beetle. Manual - part 904

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Check coolant level and top-off if necessary.  

Vehicles through Model Year2001 

When the engine is at normal operating temperature, the coolant level must be on the max. mark. 

When the engine is cold, the coolant level must be between the min. and max. marks. 

Vehicles from Model Year 2002 

When the engine is at normal operating temperature, the coolant level must be at the upper marking of the 
shaded field. 

When the engine is cold, the coolant level should be at approximately the middle of the shaded field. 

RADIATOR, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray  

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VAG 1331 Torque wrench (5 to 50 N.m)  

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VAG 1921 Spring-type clip pliers  

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Anti-freeze tester 

Fig. 13: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant. See DRAINING .  

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Remove front bumper. 

See FRONT FENDER, ASSEMBLY OVERVIEW .

tank. Cover cap with a cloth and open carefully.

 

2003 Volkswagen New Beetle GLS 

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

  

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Pull coolant hoses off radiator.  

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Pull connectors off thermo-switch and coolant fan.  

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Remove tensioning element for ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING .  

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Remove radiator securing bolts and take out radiator.  

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Observe additional information and removal work. See ADDITIONAL INFORMATION AND 
REMOVAL WORK ON VEHICLES WITH AIR CONDITIONER .  

Installing 

Installation is carried out in the reverse order; when doing this note the following: 

Filling with coolant. See FILLING . 

Additional information and removal work on vehicles with air conditioner 

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Repair retaining clamps of coolant lines if necessary.  

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Secure radiator at chassis before removing lock carrier.  

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Remove condenser from radiator and secure to lock carrier.  

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Secure condenser at chassis for removal of radiator.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray  

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VAG 1331 Torque wrench (5 to 50 N.m)  

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VAG 1921 Spring-type clip pliers  

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Anti-freeze tester 

NOTE:

Vehicles with air conditioner:

WARNING:

The air conditioner refrigerant circuit must not be opened.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure 
that the pipes and hoses are not stretched, kinked or bent.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant. See DRAINING .  

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Remove ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Remove upper and center toothed belt guard. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING .  

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Take toothed belt off coolant pump toothed belt sprocket. See TOOTHED BELT, REMOVING, 
INSTALLING AND TENSIONING .  

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Unscrew coolant pump securing bolts -1- and remove coolant pump -2-. 

NOTE:

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Always replace seals and gaskets.  

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The lower part of the toothed belt guard need not be removed.  

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The toothed belt should be left in position on the crankshaft sprocket.  

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Cover toothed belt with a cloth to protect it from coolant before removing 
coolant pump.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 15: Unscrewing Coolant Pump Securing Bolts And Removing Coolant Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is carried out in the reverse order; when doing this note the following: 

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Moisten new O-ring with coolant.  

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Insert coolant pump into cylinder block and tighten securing bolts. 

Tightening torque: 15 N.m 

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Install toothed belt and adjust valve timing. See TOOTHED BELT, REMOVING, INSTALLING 
AND TENSIONING .  

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Install ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Filling with coolant. See FILLING .  

THERMOSTAT, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray  

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VAG 1331 Torque wrench (5 to 50 N.m)  

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VAG 1921 Spring-type clip pliers  

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Anti-freeze tester 

 

2003 Volkswagen New Beetle GLS 

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