Volkswagen New Beetle. Manual - part 905

 

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Volkswagen New Beetle. Manual - part 905

 

 

Fig. 16: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

Vehicles with air conditioner: Observe additional information and removal instructions. See ADDITIONAL 
INFORMATION AND REMOVAL INSTRUCTIONS FOR VEHICLES WITH AIR CONDITIONER
 . 

z

Pull coolant hose off connecting flange -3-.  

z

Unbolt securing bolts -4- of connecting flange -3- and remove connecting flange -3- with thermostat -1-. 

Fig. 17: Unbolting Securing Bolts Of Connecting Flange And Removing Connecting Flange With 
Thermostat
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

NOTE:

z

Always replace seals and gaskets. 

z

Drain coolant. See DRAINING .  

 

2003 Volkswagen New Beetle GLS 

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

  

Installation is carried out in the reverse order, when doing this note the following: 

z

Moisten new O-ring -2- with coolant.  

z

Insert thermostat -1- into connecting flange -3- and turn 1/4 turn (90°) to right.  

z

Install connecting flange -3- with thermostat -1- into engine block.  

z

Tighten securing bolts -4-. 

Tightening torque: 15 N.m 

Fig. 18: Tightening Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Fill with coolant. See FILLING .  

AFTER-RUN COOLANT PUMP -V51-, CHECKING 

Special tools and equipment 

z

VAG 1527 B LED test light 

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 19: Identifying VAG 1527 B LED Test Light 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VAG 1594 A Auxiliary test set  

z

Wiring diagram 

Fig. 20: Identifying VAG 1594 A Auxiliary Test Set 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking conditions 

z

Fuse No. 16 OK. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 21: Identifying Fuse No. 16 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

z

Pull 2 pin connector off After-run coolant pump -V51 -.  

z

Connect contacts of After-run coolant pump -V51- to battery using auxiliary cables from VAG 1594. 

After-run coolant pump must run. 

Fig. 22: Connecting Contacts Of After-Run Coolant Pump To Battery 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the after-run coolant pump does not run: 

z

Replace after-run coolant pump -V51-. 

NOTE:

Fuse box is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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