Volkswagen New Beetle. Manual - part 917

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Stage 2 ON: 99 to 105° C OFF: 91 to 98° C  

22. Bracket 

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For radiator  

23. Bracket 

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For radiator  

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Note installation position  

Fig. 1: Exploded View Of Cooling System Components (Body Side) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM COMPONENTS, ENGINE SIDE 

1. 25 N.m (18 ft lb)  

2. Coolant pump 

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Check arm for ease of movement  

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Note installation position  

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Removing and installing: See COOLANT PUMP, REMOVING AND INSTALLING .  

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If damaged and leaking replace complete assembly  

3. O-ring 

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Always replace  

4. EGR cooler  

5. To expansion tank 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

6. Coolant hose, upper 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

7. To cylinder head 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - 1.9L 4-Cyl. ALH - New Beetle

  

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

8. To heat exchanger 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

9. From heat exchanger 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

10. Coolant pipe 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

11. 10 N.m (7 ft lb)  

12. To expansion tank, lower 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

13. EGR cooler supply 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

14. Connection 

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With glow plugs -Q7- for auxiliary heater  

15. To top of radiator 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

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Clipped to bulkhead  

16. O-ring 

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Make sure it is seated securely  

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Always replace  

17. To bottom of radiator 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

18. Connection 

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For thermostat  

19. Coolant thermostat 

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Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING .  

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Observe installed position. See THERMOSTAT, REMOVING AND INSTALLING .  

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Checking: heat-up thermostat in water  

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Opening starts at 85° C approx.  

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Ends approx. 105° C  

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Opening lift 7 mm minimum  

20. Oil cooler 

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Removing and installing: See PART II (item -3-) 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - 1.9L 4-Cyl. ALH - New Beetle

  

Fig. 2: Exploded View Of Cooling System (Engine Side) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTIONS, DIAGRAM 

1. Radiator  

2. Oil cooler  

3. Coolant pump  

4. Engine block  

5. Expansion tank  

6. Intake manifold  

7. EGR cooler  

8. Heating system heat exchanger  

9. Coolant pipe  

10. Transmission cooler 

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Vehicles with automatic transmission  

11. Coolant hose, upper  

12. Coolant hose, lower 

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - 1.9L 4-Cyl. ALH - New Beetle

  

Fig. 3: Identifying Coolant Hose Connections (Coolant Flow Diagram) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM, DRAINING AND FILLING 

Special tools and equipment 

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VAG 1306 Drip tray for VAG1202A 

Fig. 4: Identifying Vag 1306 Drip Tray For Vag1202A 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1921 Hose clip pliers  

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Anti-freeze tester 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - 1.9L 4-Cyl. ALH - New Beetle