Volkswagen New Beetle. Manual - part 920

Fig. 13: Removing Thermostat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

 

2003 Volkswagen New Beetle GLS 

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

  

Installation is carried out in the reverse order. Note the following during installation: 

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Moisten new O-ring -3- with coolant.  

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Insert thermostat -4- in connection -2- and turn 1/4 turn (90°) to right. 

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Install thermostat -4- into engine block.  

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Tighten mounting bolt -1- to 15 N.m (11 ft lb).  

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Fill engine with coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

Engine Cooling System - New Beetle, 1.9L 4-Cyl. - BEW 

COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and 
V.A.G 1274/9. 

Cooling system components - body side. See COOLING SYSTEM COMPONENTS - BODY SIDE . 

Cooling system components - engine side. See COOLING SYSTEM COMPONENTS - ENGINE SIDE . 

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM 

Draining and filling with coolant. See COOLANT, DRAINING AND FILLING . 

Coolant mixing ratios. See COOLANT, DRAINING AND FILLING . 

COOLING SYSTEM COMPONENTS - BODY SIDE 

1. Radiator 

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Removing and installing. See RADIATOR, REMOVING AND INSTALLING  

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

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Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

NOTE:

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When the engine is warm, the cooling system is under pressure. If 
necessary, release the pressure before beginning repair work.  

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Hoses are secured with spring-type clips. In case of repair, only use 
spring-type clips.  

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Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended 
for installing spring-type clips.  

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When installing coolant hoses, route stress-free so that they do not come 
into contact with other components (observe markings on coolant 
connection and hose).  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

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After replacing, replace entire quantity of coolant  

2. O-ring 

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Always 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. Connector  

5. Cap 

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Check with coolant 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 to 1.6 bar  

6. 2.5 N.m  

7. Expansion tank 

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

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Test pressure: 1.4 to 1.6 bar  

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Observe markings. See COOLANT, DRAINING AND FILLING .  

8. To coolant pipe 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

9. Air ducting  

10. 5 N.m  

11. Supplementary fan 

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Only models with optional equipment  

12. Fan ring 

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For additional fan  

13. Fan ring  

14. Coolant fan  

15. Bracket 

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For coolant fan connector.  

16. 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 .  

17. O-ring 

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Always replace  

18. Coolant Fan Control (FC) Thermal Switch -F18-, 35 N.m 

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For electric fan  

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Switching temperatures: 

1. Speed 

 

2003 Volkswagen New Beetle GLS 

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