Volkswagen New Beetle. Manual - part 945

Fig. 9: Identifying Noise Insulation Mounting Points (New Beetle)
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

Fig. 10: Identifying Noise Insulation Mounting Points (New Beetle Convertible) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

2. Unscrew drain plug (arrow), and drain coolant from radiator. See Fig. 6 .  

3. Remove coolant hose from oil cooler, and drain coolant from engine. See Fig. 7 . 

4. On vehicles with expansion tank MAX/MIN markings, close drain plug at radiator. Connect oil cooler 

hoses. Fill cooling system with recommended coolant mixture. See COOLING SYSTEM 
SPECIFICATIONS . Install expansion tank cap. Turn off A/C and heater controls. Start engine, and 
raise engine speed to 2000 RPM for approximately 3 minutes. Allow engine to idle, until coolant fan 

CAUTION: DO NOT mix Green with Lilac coolant. Mixing these coolant types will 

cause severe engine damage. Use ONLY G 012 A8 F Lilac coolant. 
See COOLING SYSTEM SPECIFICATIONS .

NOTE:

If filling cooling system, using VAG 6096 Charging Unit, go to step 9 .

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

turns on. Turn ignition off.  

5. Check coolant level, and top off as necessary. When engine is at normal operating temperature, coolant 

level must be on MAX mark, on expansion tank. See Fig. 11 . When engine is cold, coolant level must be 
between MIN and MAX marks, on expansion tank. 

Fig. 11: Identifying Expansion Tank Markings 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

6. On vehicles without expansion tank markings, close drain plug at radiator. Connect oil cooler hoses. Fill 

cooling system with recommended coolant mixture. See COOLING SYSTEM SPECIFICATIONS . 
Slowly fill expansion tank with coolant to upper hatch mark (arrow). See Fig. 12 . Install expansion tank 
cap. 

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

Fig. 12: Identifying Expansion Tank Hatch Marks 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

7. Turn off A/C and heater controls. Start engine, and raise engine speed to 2000 RPM for approximately 3 

minutes. Allow engine to idle, until coolant fan turns on. Turn ignition off.  

8. Check coolant level, and top off as necessary. When engine is at normal operating temperature, coolant 

level must be at upper hatch mark, on expansion tank. See Fig. 12 . When engine is cold, coolant level 
should be around middle of hatch mark, on expansion tank.  

9. If VAS 6096 Charging Unit is available, close drain plug at radiator. Connect oil cooler hoses. Fill 

cooling system according to VAS 6096 Charging Unit instruction manual. Fill cooling system with 

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

recommended coolant mixture. See COOLING SYSTEM SPECIFICATIONS .  

SERVICING 

Coolant does not usually need replacing. In case of larger repairs when coolant needs to be drained, new coolant 
must be used because, old has been exposed to oxidation and dirt. Flush cooling system when replacing coolant. 
To flush, fill system with clear water, and run engine for approximately 2 minutes. Drain cooling system. See 
DRAINING, FILLING & BLEEDING . Flushing system should remove most coolant residue. 

Coolant to water ratio must not exceed 60%. Frost protection and cooling efficiency will decrease if the 
percentage of coolant is too high. For coolant to water ratio, see COOLANT MIXTURE 
RECOMMENDATIONS table under COOLING SYSTEM SPECIFICATIONS. 

ADJUSTMENTS 

If belt is to be reused, mark direction of rotation prior to removing drive belt. Serpentine belt is self-adjusting. 
For proper belt routing, see DRIVE BELT ROUTING . 

DRIVE BELT ROUTING 

WARNING:

Cooling system is pressurized, when engine is at operating temperature. 
Wear gloves, and other appropriate protection. Slowly and carefully 
release system pressure, before performing any repairs.

NOTE:

Serpentine belt is self-adjusting. See Fig. 13 or Fig. 14 .

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)