Volkswagen New Beetle. Manual - part 2002

 

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Volkswagen New Beetle. Manual - part 2002

 

 

CAUTION: Before beginning repairs on the electrical system: 

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Obtain the anti-theft radio security code.  

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Switch the ignition off.  

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Disconnect the battery Ground (GND) strap.  

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After reconnecting battery, re-code and check operation of anti-theft 
radio. Also check operation of clock and power windows according 
to Repair Manual and/or Owner's Manual.  

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Immediately plug open connections on A/C components to prevent 
dirt and moisture contamination.  

NOTE:

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Before carrying out any work on the A/C refrigerant system, refer to A/C 
refrigerant system safety measures, See A/C refrigerant system .  

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Except where indicated with *, all system components illustrated must 
only be serviced or replaced after discharging refrigerant system.  

NOTE:

During servicing, all couplings, fittings and related fasteners must be torqued to 
specifications.

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

Fig. 20: Identifying A/C Refrigerant System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

The following list refers to items in Fig. 20 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

1. Sealing plug 

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15 N.m (11 ft. lb)  

2. O-ring 

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10.8 mm; 1.8 mm  

3. Receiver drier  

4. O-ring 

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10.8 mm; 1.8 mm  

5. Refrigerant pipe 

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From receiver drier to expansion valve  

6. Bolt 

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15 N.m (11 ft. lb)  

7. A/C pressure switch -F129- (4-Pin) or high pressure sensor -G65- (3-Pin) 

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Depending on engine type, refrigerant systems have either an A/C pressure switch -F129- or high 
pressure sensor -G65- instralled. Refer to system wiring diagrams.  

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Checking -F129-, See A/C pressure switch -F129-, checking .  

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Checking -G65-, See High pressure sensor -G65-  

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Removing and installing, See Removing And Installing A/C Pressure Switch -F129- And High 
Pressure Sensor -G65-
  

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Component can be removed without discharging refrigerant system  

8. O-ring 

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10.8 mm; 1.8 mm  

9. Refrigerant pipe  

10. Threaded plate  

11. O-ring 

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10.8 mm; 1.8 mm  

12. Expansion valve  

13. Bolt 

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8 N.m (71 in lb)  

14. O-ring 

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14 mm; 1.8 mm  

15. High pressure service valve 

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Only use Kent Moore ACR4 or equivalent  

16. Refrigerant pipe  

17. Low pressure service valve 

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Only use Kent Moore ACR4 or equivalent  

18. O-ring 

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7,6 mm; 1.8 mm  

19. Evaporator 

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

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In heater/evaporator unit  

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Removing, See Heater/evaporator unit, disassembly and assembly  

20. O-ring 

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16.7 mm; 1.8 mm  

21. Insulation  

22. O-ring 

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7,6 mm; 1,8 mm  

23. Bolt 

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8 N.m (71 in lb)  

24. Refrigerant hose 

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From compressor to condenser  

25. Bolt 

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15 N.m (11 ft. lb)  

26. O-ring 

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10.8 mm; 1.8 mm  

27. Condenser 

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Removing and installing, See Condenser, removing and installing  

28. Compressor 

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Sanden SD7-V16  

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Removing and installing compressor bracket, See Compressor bracket, removing and installing  

29. O-ring 

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14.3 mm; 2.4 mm  

30. Bolt 

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20 N.m (15 ft. lb)  

31. O-ring 

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10.8 mm; 1.8 mm  

32. A/C clutch -N25-* 

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Sanden  

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Servicing, See A/C clutch -N25-, servicing (Sanden)  

33. Refrigerant hose  

34. O-ring 

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10.8 mm; 1.8 mm  

35. Damper  

CONDENSER, REMOVING AND INSTALLING 

First do the following:  

 

2003 Volkswagen New Beetle GLS 

1998-2004 HVAC Air Conditioning - New Beetle

  

 

 

 

 

 

 

 

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