Volkswagen New Beetle. Manual - part 909

 

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Volkswagen New Beetle. Manual - part 909

 

 

Installing 

Installation is performed in reverse order. Note the following: 

z

Fill with coolant. See COOLANT, DRAINING AND FILLING .  

Additional information and assembly work on models with an A/C system 

z

Release refrigerant lines/hoses from retainers/clamps if necessary.  

z

Secure radiator to body before removing lock carrier.  

z

To remove radiator, secure condenser to body.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray for VAG1202A  

z

V.A.G 1331 Torque wrench (5 to 50 N.m)  

z

VAS 5024 Assembly tool for spring-type clips 

Fig. 11: Special Tools And Equipment (Coolant Pump)  
Courtesy of VOLKSWAGEN OF AMERICA, INC.

SYSTEM .  

CAUTION: The air conditioning system refrigerant circuit must not be opened.

NOTE:

To prevent damage to the condenser as well as to the refrigerant lines, ensure 
that lines and hoses are not stretched, kinked or bent.

 

2003 Volkswagen New Beetle GLS 

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

  

Removing 

z

Drain coolant. See COOLANT, DRAINING AND FILLING .  

z

Remove toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

z

Remove coolant pump securing bolts -1- and remove coolant pump -2- carefully. 

Fig. 12: Removing Coolant Pump And Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in reverse order. Note the following: 

z

Clean or smooth sealing surface for O-ring.  

z

Moisten new O-ring -3- with coolant.  

z

Insert coolant pump -2- into cylinder block and tighten securing bolts -1-. 

Tightening torque: 15 N.m 

z

Install toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

z

Fill with coolant. See COOLANT, DRAINING AND FILLING 

NOTE:

Always replace seals and gaskets.

NOTE:

The coolant pump plug faces downward.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Identifying Coolant Pump And Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

THERMOSTAT, REMOVING AND INSTALLING 

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray  

z

V.A.G 1331 Torque wrench (5 to 50 N.m)  

z

VAS 5024 Assembly tool for spring-type clips 

Fig. 14: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

NOTE:

z

Always replace seals and gaskets. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Drain coolant. See COOLANT, DRAINING AND FILLING .  

z

Remove coolant hose from pipe union.  

z

Remove securing bolts -1- of pipe union -2- and remove pipe union -2- with thermostat -4-.  

z

Turn thermostat -4- 1/4 turn (90°) to left and remove from pipe union -2-. 

Fig. 15: Removing Pipe Union With Thermostat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in reverse order. Note the following: 

z

Coat new O-ring -3- with coolant and install to pipe union -2-.  

z

Insert thermostat -4- into pipe union -2- and turn 1/4 (90°) to right. 

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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