Volkswagen New Beetle. Manual - part 915

 

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Volkswagen New Beetle. Manual - part 915

 

 

Fig. 18: Locating Main Fuses (Left Front Corner Of Engine Compartment) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Remove left side sound insulation: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

z

Disconnect 3-pin connector from Coolant Fan Control (FC) thermal switch -F18-.  

z

Bridge contact -1- and contact -2- of connector with auxiliary cables from V.A.G 1594 A.  

Connector type A 

Fig. 19: Identifying Coolant Fan Connector Type A 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Connector type B 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 20: Identifying Coolant Fan Connector Type B 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Connector type C 

Fig. 21: Identifying Coolant Fan Connector Type C 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

1st speed for Coolant fan -V7- and Right coolant fan -V35- must start 

z

Switch on ignition.  

z

Bridge contact -2- and contact -3- of connector with auxiliary cables from V.A.G 1594 A. 

2nd speed for Coolant fan -V7- and Right coolant fan -V35- must start. 

If 1st or 2nd speeds of fans do not run: 

z

Locate and eliminate open circuit using wiring diagram: 

 

2003 Volkswagen New Beetle GLS 

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

  

See appropriate SYSTEM WIRING DIAGRAMS article.

If no wiring fault is detected: 

z

Replace Coolant fan -V7- or Right coolant fan -V35-.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray  

z

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

z

VAS 5024 Assembly tool for spring-type clamps 

Fig. 22: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Drain coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

z

Remove ribbed belt, See RIBBED BELT, REMOVING AND INSTALLING .  

z

Remove tensioning element for ribbed belt. 

NOTE:

z

Always replace seals and gaskets.  

z

The lower section of the toothed belt guard need not be removed.  

z

The toothed belt should be left in position on the crankshaft pulley.  

z

Cover the toothed belt with a cloth to protect it from coolant before 
removing the coolant pump.  

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove upper and center sections of toothed belt guard.  

z

Take toothed (timing) belt off coolant pump toothed belt pulley. See TOOTHED BELTS, 
REMOVING, INSTALLING AND TENSIONING
 .  

z

Unscrew securing bolt -1- for rear toothed belt guard -2-. See Fig. 23 .  

z

Unscrew securing bolts -5- for coolant pump and remove coolant pump -4-. 

Fig. 23: Removing Coolant Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in the reverse sequence. Note the following: 

z

Moisten new O-ring -3- with coolant. See Fig. 24 .  

z

Install coolant pump -4-. Installation position: Coolant pump sealing plug faces downward.  

z

Tighten securing bolts -5- to 15 N.m.  

z

Tighten securing bolt -1- for rear toothed belt guard -2- on cylinder head to 20 N.m 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  913  914  915  916   ..