Volkswagen New Beetle. Manual - part 958

Fig. 9: Identifying Coolant Fan Control Thermo Switch Contacts (Type C) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

4. Bridge contact 2 and contact 3 of connector with jumper wire. Turn ignition on, with engine off. Fan 

should run at high speed.  

5. If fan(s) do not run, check for open circuit between connector and fans. Also check for faulty fan ground 

circuit. Repair as necessary. If wiring is OK, replace fan.  

REMOVAL & INSTALLATION 

A/C HIGH PRESSURE SENSOR OR SWITCH 

When replacing switch or sensor (B), always use new "O" ring (A). Tighten to specification. See TORQUE 
SPECIFICATIONS .  

TORQUE SPECIFICATIONS 

NOTE:

A/C high pressure sensor or switch can be removed without discharging 
refrigerant system. 

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

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TORQUE SPECIFICATIONS 

WIRING DIAGRAMS 

1999 

See COOLING FAN in SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

2000 

See COOLING FAN in SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

2001 

See COOLING FAN in SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

2002 

See COOLING FAN in SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

2003 

See COOLING FAN in SYSTEM WIRING DIAGRAMS in ELECTRICAL.  

2004 

See appropriate COOLING FAN wiring diagram in SYSTEM WIRING DIAGRAMS in ELECTRICAL. 

Application 

Ft. Lbs. (N.m) 

Coolant Fan Control Thermo Switch 

26 (35) 

INCH Lbs. (N.m)

A/C High Pressure Sensor or Switch 

(1)

 44 (5) 

(1)

A/C refrigerant does not need to be discharged. Use new "O" ring.

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

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1998-2004 ENGINE

Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD) 

COOLING SYSTEM, SERVICING 

COOLING SYSTEM, GENERAL INFORMATION 

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

z

Route all types of 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.  

z

Ensure sufficient clearance to all moving or hot components.  

NOTE:

z

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

z

Hoses are secured with spring-type clamps. In cases of repair only use 
spring-type clamps.  

z

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

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. 

Components of cooling system body side, See COOLING SYSTEM COMPONENTS - BODY SIDE, 
REMOVING AND INSTALLING . 

Components of cooling system engine side, See COOLING SYSTEM COMPONENTS - ENGINE SIDE, 
REMOVING AND INSTALLING . 

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM 

Fig. 1: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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).  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)