Volkswagen New Beetle. Manual - part 963

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Fill with coolant up to max. mark on expansion tank. 

Fig. 11: Identifying Expansion Tank (Vehicles With Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Fit expansion tank cap.  

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Switch off heater and air conditioner.  

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Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes.  

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Run engine until coolant fan starts.  

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Switch off ignition. 

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Check coolant level and top up if necessary. 

WARNING:

Steam can be released when removing the cap from the expansion 
tank. Cover the cap with a cloth and open carefully.

 

2003 Volkswagen New Beetle GLS 

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

  

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

Fig. 12: Identifying Expansion Tank (Vehicles With Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

When engine is cold coolant level must be between min. and max. marks. 

Vehicles without max. expansion tank marking 

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Fill coolant slowly up to upper hatched field mark (arrow) on expansion tank. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Identifying Expansion Tank (Vehicles Without Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Close expansion tank.  

z

Switch off heater and air conditioner.  

z

Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes.  

z

Run engine until coolant fan starts.  

z

Switch off ignition. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Check coolant level and top up if necessary: 

Coolant level must be at upper hatched field mark when engine is at operating temperature (arrow). 

Fig. 14: Identifying Expansion Tank (Vehicles Without Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

WARNING:

Steam can be released when removing the cap from the expansion 
tank. Cover the cap with a cloth and open carefully.

 

2003 Volkswagen New Beetle GLS 

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