Volkswagen New Beetle. Manual - part 910

 

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Volkswagen New Beetle. Manual - part 910

 

 

Fig. 16: Installing Connecting Union With Thermostat
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Install connecting union -2- with thermostat -4- into engine block.  

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Tighten securing bolts -1-. 

Tightening torque: 15 N.m 

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Fill with coolant. See COOLANT, DRAINING AND FILLING .  

GLOW PLUGS, CHECKING 

Special tools and equipment 

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V.A.G 1594 A Adapter set 

Fig. 17: Identifying Special Tools And Equipment (V.A.G 1594 Adapter Set) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1527 B Diode test lamp 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 18: Identifying Special Tools And Equipment (V.A.G 1527 B Diode Test Lamp) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Battery voltage at least 11.5 V  

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Ignition switched off  

Work sequence 

Checking electric activation of glow plugs: 

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Disconnect connector -1- from glow plugs.  

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Connect diode test lamp cable with clamps from adapter set to battery positive (+).  

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Insert diode test lamp test pick to every glow plug one after another. 

Fig. 19: Using Diode Test Lamp To Check Glow Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Diode lights up: glow plug is OK 

Diode does not light up: 

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Replace glow plug. See GLOW PLUGS, CHECKING 

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD) 

COOLING SYSTEM, SERVICING 

COOLING SYSTEM, GENERAL INFORMATION 

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and 

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

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Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

NOTE:

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When the engine is warm the cooling system is under pressure. If 
necessary release the pressure before beginning repair work.  

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Hoses are secured with spring-type clamps. In cases of repair only use 
spring-type clamps.  

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Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended 
for installing spring-type clamps. 

Fig. 1: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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When installing coolant hoses route stress-free so that they do not come 
into contact with other components (observe markings on coolant 
connection and hose).  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

 

 

 

 

 

 

 

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