Volkswagen New Beetle. Manual - part 921

on: 92...97 °C 

off: 84...91 °C 

2. Speed 

on: 99...105 °C 

off: 91...98 °C 

19. Bracket 

z

For bottom of radiator  

z

Note installed position  

20. Bracket 

z

For top of radiator  

z

Note installed position  

Fig. 1: Identifying Cooling System Components - Body Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM COMPONENTS - ENGINE SIDE 

1. 15 N.m  

2. Coolant pump 

z

Check for ease of movement  

z

Note installed position  

z

Removing and installing. See COOLANT PUMP, REMOVING AND INSTALLING  

3. O-ring 

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Always replace  

4. Bypass flap 

z

For exhaust gas recirculation radiator  

5. Radiator 

z

For exhaust gas recirculation  

6. To top of expansion tank 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

7. Upper front coolant pipe 

z

Installed with cylinder head cover on front side of cylinder head  

z

One unit with fuel lines  

8. Connection union  

9. Seal 

z

Check for secure seating  

z

Always replace  

10. Securing clip 

z

Check for secure seating  

11. Engine Coolant Temperature (ECT) Sensor -G62- 

z

With Engine Coolant Temperature (ECT) Sensor -G2-  

12. 10 N.m  

13. Heating flange 

z

For glow plugs  

14. Glow plugs 

z

25 N.m  

z

Checking. See GLOW PLUGS, CHECKING .  

15. Quick-action coupling  

16. To heat exchanger 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

17. From heat exchanger 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

18. Distributor  

19. To top of radiator 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

20. Coolant pipe  

21. 40 N.m  

22. To bottom of expansion tank 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

23. Transmission oil cooler  

 

2003 Volkswagen New Beetle GLS 

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

  

24. To bottom of radiator 

z

Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

25. Oil cooler 

z

Removing and installing. See PART 2: DISASSEMBLING OIL FILTER BRACKET .  

26. Connection union 

z

For thermostat  

27. Thermostat 

z

Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING .  

z

Observe installed position. See THERMOSTAT, REMOVING AND INSTALLING .  

z

Checking: Heat-up thermostat in water  

z

Starts to open: approx. 85° C  

z

Ends: approx. 105° C  

z

Opening stroke: min. 7 mm  

Fig. 2: Identifying Cooling System Components - Engine Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTION DIAGRAM 

1. Radiator  

2. Oil cooler  

3. Thermostat  

4. Coolant pump  

5. Cylinder block  

6. Expansion tank  

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

7. Intake manifold  

8. Radiator 

z

For exhaust gas recirculation  

9. Bypass flap 

z

For exhaust gas recirculation radiator  

10. Connection union 

z

To cylinder block  

11. Heater unit heat exchanger  

12. Quick-action coupling  

13. Coolant pipe  

14. Transmission oil cooler  

15. Distributor  

16. Upper front coolant pipe  

Fig. 3: Coolant Hose Connection Diagram 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT, DRAINING AND FILLING 

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray for VAG1202A  

z

VAS 5024 Assembly tool for spring-type clips  

Not illustrated: 

z

VAS 6096 Coolant system charging unit 

 

2003 Volkswagen New Beetle GLS 

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