Volkswagen New Beetle. Manual - part 912

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

23. O-ring 

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Replace if damaged  

Fig. 3: Exploded View Of Engine Side Cooling System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTION DIAGRAM 

Engine code AEG (up to Model Year 1998) 

1. Radiator  

2. Oil cooler  

3. Coolant pump/coolant thermostat  

4. Cylinder head/cylinder block  

5. Expansion tank  

6. Intake manifold  

7. Throttle valve control module  

8. Union  

9. Heating system heat exchanger  

10. Coolant pipe  

11. ATF cooler 

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Only models with an automatic transmission 

NOTE:

Engine codes AEG (from Model Year 1999), AVH, AZG, BDC, BEV, BGD, see 
ENGINE CODES AEG (FROM MODEL YEAR 1999), AVH, AZG, BDC, BEV, BGD .

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 4: Coolant Hose Connection Diagram (Engine Code AEG Up To Model Year 1998) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AEG (from Model Year 1999), AVH, AZG, BDC, BEV, BGD 

1. Radiator  

2. Oil cooler  

3. Coolant pump/coolant thermostat  

4. Cylinder head/cylinder block  

5. Expansion tank  

6. Intake manifold  

7. Throttle valve control module  

8. Connecting unions  

9. Heating system heat exchanger  

10. Quick-action coupling  

11. Coolant pipe  

12. ATF cooler 

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Only models with an automatic transmission 

NOTE:

The following list refers to items in Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Coolant Hose Connection Diagram (Engine Codes AEG From Model Year 1999, AVH, AZG, 
BDC, BEV, BGD) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM, DRAINING AND FILLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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T10007 Refractometer  

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V.A.G 1306 Drip tray  

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Torque wrench VAG 1331  

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VAS 5024 Assembly tool for spring-type clamps  

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Adapter for expansion tank VAG 1274/8  

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VAS 6096 Coolant system charging unit 

Fig. 6: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Draining 

 

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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Open cap on coolant expansion tank.  

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Remove sound insulation tray: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Place drip tray VAG 1306 under vehicle.  

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Remove drain plug (arrow) to drain coolant from radiator. 

Fig. 7: Removing Radiator Drain Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove coolant hose from oil cooler (arrow) to drain coolant from engine. 

WARNING:

Steam can be released when removing the cap from the expansion tank. 
Cover the cap with a cloth and open carefully.

NOTE:

Observe waste disposal regulations!

 

2003 Volkswagen New Beetle GLS 

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