Volkswagen New Beetle. Manual - part 911

V.A.G 1274/9. 

Components of cooling system body side, See COOLING SYSTEM COMPONENTS - BODY SIDE, 
REMOVING AND INSTALLING . 

Components of cooling system engine side, See COOLING SYSTEM COMPONENTS - ENGINE SIDE, 
REMOVING AND INSTALLING . 

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM 

Draining and filling with coolant, See COOLING SYSTEM, DRAINING AND FILLING . 

Coolant mixing ratios, See COOLING SYSTEM, DRAINING AND FILLING 

COOLING SYSTEM COMPONENTS - BODY SIDE, REMOVING AND INSTALLING 

1. Radiator 

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Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

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After replacement replace entire coolant amount  

2. O-ring 

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Replace  

3. Upper coolant hose 

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Secured to radiator with retaining clip  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

4. 4 N.m  

5. Cover 

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Check with cooling system tester V.A.G1274 and adapter V.A.G 1274/9  

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Pressure relief valve must open at a pressure of 1.4...1.6 bar  

6. 2 N.m  

7. Expansion tank 

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Perform leak test on cooling system with cooling system tester V.A.G 1274 and adapter 
V.A.G1274/8  

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Test pressure 1.4...1.6 bar  

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Observe markings, See COOLING SYSTEM, DRAINING AND FILLING  

8. Connector  

9. To coolant pipe 

NOTE:

Coolant hose connection diagram, See COOLANT HOSE CONNECTION 
DIAGRAM

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

10. Air ducting  

11. 10 N.m  

12. Right coolant fan -V35- 

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Only models with optional equipment  

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Checking, See COOLANT FAN, CHECKING  

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Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

13. Fan ring 

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For right coolant fan  

14. Retaining clip 

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Check if seated securely  

15. Fan ring  

16. Coolant fan - V7- 

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Checking, See COOLANT FAN, CHECKING  

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Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

17. Retainer 

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For coolant fan connector  

18. Lower coolant hose 

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Secured to radiator with retaining clip  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

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Check if seated securely  

19. Coolant Fan Control (FC) thermal switch -F18-, 35 N.m 

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For electric fan  

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Switching temperatures: 1. stage on: 92...97°C, off: 84...91°C; 2. stage on: 99...105 C, off: 91...98°
C  

20. Retainer 

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For bottom of radiator  

21. Retainer 

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For top of radiator  

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Observe installed position  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

Fig. 2: Exploded View Of Body Side Cooling System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM COMPONENTS -ENGINE SIDE, REMOVING AND INSTALLING 

1. Heating system heat exchanger  

2. Connector 

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4-pin  

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Gold plated contacts for ECT sensor - G62-  

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

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For engine control module  

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With ECT sensor -G2-  

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Gold plated contacts for ECT sensor -G62-  

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Release pressure in cooling system if necessary before removing components  

4. Connector 

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2-pin  

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Only for engine code AEG until Model Year 1999  

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Only vehicles with air conditioner with 4-pin A/C Pressure Switch -F129-  

5. A/C cut-out thermal switch -F163- 

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Only for engine code AEG until Model Year 1999  

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Only vehicles with air conditioner with 4-pin A/C Pressure Switch -F129-  

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Vehicles with air conditioner only, otherwise blind plug  

6. Coolant pipe 

NOTE:

Coolant hose connection diagram, See COOLANT HOSE CONNECTION 
DIAGRAM

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

7. Retaining clip 

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Check if seated securely  

8. 10 N.m  

9. To bottom of expansion tank 

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

10. To top of radiator 

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

11. O-ring 

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Replace  

12. Connecting unions  

13. To bottom of radiator 

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

14. Oil cooler 

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Removing and installing, See PART II (OIL FILTER HOUSING, DISASSEMBLING AND 
ASSEMBLING) .  

15. 15 N.m  

16. Coolant thermostat 

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Checking: Heat up thermostat in water  

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Starts to open: approx. 86°C  

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Opening stroke: min. 7 mm  

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Removing and installing, See THERMOSTAT, REMOVING AND INSTALLING  

17. 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 BELTS, REMOVING, INSTALLING 
AND TENSIONING .  

18. 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  

19. Rear toothed belt guard  

20. 20 N.m  

21. Throttle valve control module 

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Heated by coolant  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

22. To top of expansion tank 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)