Volkswagen New Beetle. Manual - part 907

 

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Volkswagen New Beetle. Manual - part 907

 

 

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Always replace  

4. Bypass flap 

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For exhaust gas recirculation radiator  

5. Radiator 

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For exhaust gas recirculation  

6. To top of expansion tank 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

7. Upper front coolant pipe 

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Installed with cylinder head cover on front side of cylinder head  

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One unit with fuel lines  

8. Connection union  

9. Seal 

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Check for secure seating  

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Always replace  

10. Securing clip 

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Check for secure seating  

11. Engine Coolant Temperature (ECT) Sensor -G62- 

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With Engine Coolant Temperature (ECT) Sensor -G2-  

12. 10 N.m  

13. Heating flange 

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For glow plugs  

14. Glow plugs 

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25 N.m  

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Checking. See GLOW PLUGS, CHECKING .  

15. Quick-action coupling  

16. To heat exchanger 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

17. From heat exchanger 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

18. Distributor  

19. To top of radiator 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

20. Coolant pipe  

21. 40 N.m  

22. To bottom of expansion tank 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

23. Transmission oil cooler  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.9L 4-Cyl. - BEW

  

24. To bottom of radiator 

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Coolant hose connection diagram. See COOLANT HOSE CONNECTION DIAGRAM  

25. Oil cooler 

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Removing and installing. See PART 2: DISASSEMBLING OIL FILTER BRACKET .  

26. Connection union 

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For thermostat  

27. Thermostat 

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Removing and installing. See THERMOSTAT, REMOVING AND INSTALLING .  

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Observe installed position. See THERMOSTAT, REMOVING AND INSTALLING .  

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Checking: Heat-up thermostat in water  

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Starts to open: approx. 85° C  

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Ends: approx. 105° C  

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Opening stroke: min. 7 mm  

Fig. 2: Identifying Cooling System Components - Engine Side 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTION DIAGRAM 

1. Radiator  

2. Oil cooler  

3. Thermostat  

4. Coolant pump  

5. Cylinder block  

6. Expansion tank  

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.9L 4-Cyl. - BEW

  

7. Intake manifold  

8. Radiator 

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For exhaust gas recirculation  

9. Bypass flap 

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For exhaust gas recirculation radiator  

10. Connection union 

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To cylinder block  

11. Heater unit heat exchanger  

12. Quick-action coupling  

13. Coolant pipe  

14. Transmission oil cooler  

15. Distributor  

16. Upper front coolant pipe  

Fig. 3: Coolant Hose Connection Diagram 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT, DRAINING AND FILLING 

Special tools and equipment 

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T10007 Refractometer  

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V.A.G 1306 Drip tray for VAG1202A  

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VAS 5024 Assembly tool for spring-type clips  

Not illustrated: 

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VAS 6096 Coolant system charging unit 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.9L 4-Cyl. - BEW

  

Fig. 4: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Draining 

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Remove cap from coolant expansion tank.  

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Remove center and left side sound insulation: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Remove drain plug (arrow) from radiator to drain. 

Fig. 5: Removing Drain Plug From Radiator To Drain 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

WARNING:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 1.9L 4-Cyl. - BEW

  

 

 

 

 

 

 

 

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