Volkswagen New Beetle. Manual - part 903

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  901  902  903  904   ..

 

 

Volkswagen New Beetle. Manual - part 903

 

 

Fig. 7: Draining Coolant From Engine And Removing Coolant Hose From Oil Cooler 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Filling 

z

Only use coolant additive G 12 in accordance with TL VW 774 D. Identification: colored red.  

z

On no account must G 12 be mixed with other coolant additives!  

z

If the fluid in expansion tank is brown, G 12 has been mixed with other coolant. In this case the coolant 
must be changed.  

z

G 12 and coolant additives marked "In accordance with TL VW 774 D" prevent frost and corrosion 
damage, scaling and also raise boiling point of coolant. For this reason the system must be filled all year 
round with frost and corrosion protection additives.  

z

Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly 

NOTE:

Observe disposal regulations!

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

in countries with tropical climates.  

z

Protection against frost must be assured to about -25° C (-13° F) (in arctic climate countries to about -35° 
C (-31° F)).  

z

The coolant concentration must NOT be reduced by adding water even in warmer seasons and in warmer 
countries. The anti-freeze ratio must be at least 40%.  

z

If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only 
up to 60% (frost protection to about -40°C (-40°F)), as otherwise frost protection is reduced again and 
cooling effectiveness is also reduced.  

z

The T10007 refractometer is recommended for determining frost protection density. 

Fig. 8: Identifying T10007 Refractometer 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.  

Recommended mixture ratios: 

RECOMMENDED MIXTURE RATIOS 

z

Screw drain plug into radiator. 

Frost protection to

Antifreeze amount

G12 

(1)

Water 

(1)

-25°C (-13°F)

40%

2.0 ltr. (0.5 gallon)

3.0 ltr. (0.8 gallon)

-35°C (-31°F)

50%

2.5 ltr. (0.7 gallon)

2.5 ltr. (0.7 gallon)

(1)

The quantity of coolant can vary depending upon the vehicle equipment.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

Fig. 9: Screwing Drain Plug Into Radiator 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Push coolant hose onto oil cooler connection and secure with a spring-type clamp. 

Fig. 10: Pushing Coolant Hose Onto Oil Cooler Connection And Securing With Spring-Type 
Clamp
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles through Model Year2001 

z

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

Fig. 11: Identifying Max. Mark On Expansion Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles from Model Year 2002 

z

Slowly fill expansion tank to upper marking of shaded field with coolant. 

Fig. 12: Filling Expansion Tank To Upper Marking Of Shaded Field With Coolant 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all vehicles 

z

Install expansion tank cap.  

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 cuts-in. 

WARNING:

Steam can be released when removing the cap from the expansion 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.8L (APH, AWV & AWP)

  

 

 

 

 

 

 

 

Content   ..  901  902  903  904   ..