Volkswagen New Beetle. Manual - part 933

Fig. 8: Identifying Coolant Level Mark 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Install coolant expansion tank cap.  

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Run engine until radiator fan comes on.  

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Check coolant level and top off if necessary. 

When engine is at normal operating temperature, coolant level must be on MAX. mark 

When engine is cold, coolant level can be between MIN. and MAX. marks. 

RADIATOR, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray forVAG1202A  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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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

  

Fig. 9: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Remove front panel: 

See PLENUM CHAMBER SEALING ASSEMBLY, REMOVING AND INSTALLING . 

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Disconnect coolant hoses from radiator.  

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Disconnect connectors from thermo-switch.  

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Remove ribbed belt tensioner. See RIBBED BELT TENSIONER, REMOVING AND 
INSTALLING .  

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Remove radiator mounting bolts and take out radiator. 

Installing 

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

Engine coolant, filling. See COOLING SYSTEM, DRAINING AND FILLING . 

A/C SYSTEM, ADDITIONAL REMOVAL INFORMATION 

NOTE:

Vehicles with A/C: 

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Observe additional information and removal work. See A/C SYSTEM, 
ADDITIONAL REMOVAL INFORMATION .  

WARNING:

Do NOT open the A/C refrigerant circuit.

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove retaining clamp(s) from refrigerant lines.  

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Before removing lock support, fasten radiator to body  

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To remove radiator, fasten condenser to the body.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray forVAG1202A  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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VAG 1921 Hose clip pliers  

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Anti-freeze tester 

Fig. 10: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Remove ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING .  

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Disconnect fuel supply and return lines at fuel filter. 

NOTE:

To prevent damage to the condenser and to the refrigerant lines/hoses, make 
sure that the lines and hoses are not stretched, kinked or bent.

NOTE:

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Always replace seals and gaskets.  

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Lower part of the toothed belt guard need not be removed.  

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Toothed belt should be left in position on the crankshaft sprocket.  

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Cover toothed belt with a cloth to protect it from coolant before removing 
coolant pump.  

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove connector hose between charge air cooler and intake manifold. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING .  

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Remove fuel filter with bracket. See FUEL FILTER, SERVICING .  

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Remove belt guard upper and middle sections. See PART II .  

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Remove V-belt from camshaft sprocket, injection pump sprocket and coolant pump sprocket. See 
TOOTHED BELTS, REMOVING, INSTALLING, TENSIONING .  

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Unscrew mounting bolt -1- from pulley -2- and press downward approx. 30 mm. 

Fig. 11: Removing Mounting Bolt From Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Unscrew mounting bolts -3- from coolant pump and carefully remove coolant pump -4- between engine 
bracket and toothed belt guard.  

Installing 

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

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Moisten new O-ring -3- with clean engine coolant.  

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Insert coolant pump -4- into engine block and tighten mounting bolts -5- to 15 N.m (11 ft lb). 

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Install pulley -2- and tighten mounting bolt -1- (replace). Tightening torque: 40 N.m (30 ft lb) plus 
additional 90° (1/4 turn).  

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Install and tighten toothed belt. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING .  

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Install fuel filter with bracket.  

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Disconnect fuel supply and return lines at fuel filter.  

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Install ribbed belt. See RIBBED BELT TENSIONER, REMOVING AND INSTALLING . 

NOTE:

Coolant pump plug points downward.

 

2003 Volkswagen New Beetle GLS 

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