Volkswagen New Beetle. Manual - part 916

 

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Volkswagen New Beetle. Manual - part 916

 

 

Fig. 24: Installing Coolant Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing toothed belt and adjusting timing. See TOOTHED BELTS, REMOVING, INSTALLING 
AND TENSIONING
 . 

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Install ribbed belt tensioning element and torque to 25 N.m.  

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

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Fill with coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

THERMOSTAT, REMOVING AND INSTALLING 

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

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T10007 Refractometer  

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V.A.G 1306 Drip tray  

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V.A.G 1331 Torque wrench (5-50 N.m)  

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VAS 5024 Assembly tool for spring-type clamps 

Fig. 25: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

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Pull coolant hose off union -3-. See Fig. 26 .  

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Remove securing bolts -4- of union -3- and remove union -3- with thermostat -1-.  

NOTE:

Always replace seals and gaskets.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 26: Removing And Installing Thermostat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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

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Moisten new O-ring -2- with coolant. See Fig. 26 .  

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Fit union -3- with thermostat -1- onto engine block. 

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Tighten securing bolts -4- to 15 N.m.  

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Fill with coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

Engine Cooling System - 1.9L 4-Cyl. ALH - New Beetle 

COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING 

GENERAL INFORMATION 

Perform cooling system leakage test with VAG 1274 cooling system tester and 1274/9 adapter. 

Cooling system components, body side. See COOLING SYSTEM COMPONENTS, BODY SIDE . 

Cooling system components, engine side. See COOLING SYSTEM COMPONENTS, ENGINE SIDE . 

Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM . 

Engine coolant, draining and filling. See COOLING SYSTEM, DRAINING AND FILLING . 

Engine coolant, mixture ratios. See RADIATOR, REMOVING AND INSTALLING . 

COOLING SYSTEM COMPONENTS, BODY SIDE 

1. Radiator 

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Removing and installing. See RADIATOR, REMOVING AND INSTALLING  

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After replacing, replace entire engine coolant  

2. O-ring 

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Always replace  

3. Coolant hose, upper 

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Attached to radiator with clip  

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM  

4. Retaining clip 

NOTE:

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As the engine warms up, cooling system pressure also increases. If 
necessary, release pressure before starting repair work.  

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Hoses are secured with spring clips. When performing repairs, only use 
spring clips.  

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VAG 1921 pliers are recommended for installing spring clips.  

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

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

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Make sure it is securely seated  

5. Engine Coolant Temperature (ECT) sensor -G62- 

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Checking: 

See On Board Diagnostic (OBD) 

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With Engine Coolant Temperature (ECT) sensor -G2-  

6. 4 N.m (35 in. lb)  

7. Cap 

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Check using VAG1274 tester and VAG 1274/8 adapter  

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Test pressure 1.4 to 1.6 bar  

8. 2 N.m (18 in. lb)  

9. Coolant expansion tank 

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Perform cooling system leak check using VAG 1274 tester with VAG 1274/9 adapter  

10. Connector  

11. To cylinder head 

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Coolant hose connections, diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

12. Air ducting  

13. 10 N.m (7 ft lb)  

14. Additional fan 

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Optional equipment  

15. Fan ring 

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For auxiliary fan  

16. Retaining clip 

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Make sure it is seated securely  

17. Fan ring  

18. Coolant fan  

19. Bracket 

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For coolant fan connector  

20. Coolant hose, lower 

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Attached to radiator with clip  

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Coolant hose connection diagram. See COOLANT HOSE CONNECTIONS, DIAGRAM .  

21. Coolant fan control (FC) thermal switch -F18- 

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35 N.m (26 ft lb)  

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For electric fan  

Switching temperatures: 

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Stage 1 ON: 92 to 97° C OFF: 84 to 91° C 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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