Volkswagen New Beetle. Manual - part 919

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  917  918  919  920   ..

 

 

Volkswagen New Beetle. Manual - part 919

 

 

Fig. 9: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

Remove front panel: 

See PLENUM CHAMBER SEALING ASSEMBLY, REMOVING AND INSTALLING . 

z

Disconnect coolant hoses from radiator.  

z

Disconnect connectors from thermo-switch.  

z

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

z

Remove radiator mounting bolts and take out radiator. 

Installing 

Installation is carried out in the reverse order of the removal procedure. Note the following during installation: 

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

A/C SYSTEM, ADDITIONAL REMOVAL INFORMATION 

NOTE:

Vehicles with A/C: 

z

Observe additional information and removal work. See A/C SYSTEM, 
ADDITIONAL REMOVAL INFORMATION .  

WARNING:

Do NOT open the A/C refrigerant circuit.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove retaining clamp(s) from refrigerant lines.  

z

Before removing lock support, fasten radiator to body  

z

To remove radiator, fasten condenser to the body.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools and equipment 

z

VAG 1306 Drip tray forVAG1202A  

z

VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

z

VAG 1921 Hose clip pliers  

z

Anti-freeze tester 

Fig. 10: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

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

z

Disconnect fuel supply and return lines at fuel filter. 

NOTE:

To prevent damage to the condenser and to the refrigerant lines/hoses, make 
sure that the lines and hoses are not stretched, kinked or bent.

NOTE:

z

Always replace seals and gaskets.  

z

Lower part of the toothed belt guard need not be removed.  

z

Toothed belt should be left in position on the crankshaft sprocket.  

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

z

Remove connector hose between charge air cooler and intake manifold. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
 .  

z

Remove fuel filter with bracket. See FUEL FILTER, SERVICING .  

z

Remove belt guard upper and middle sections. See PART II .  

z

Remove V-belt from camshaft sprocket, injection pump sprocket and coolant pump sprocket. See 
TOOTHED BELTS, REMOVING, INSTALLING, TENSIONING .  

z

Unscrew mounting bolt -1- from pulley -2- and press downward approx. 30 mm. 

Fig. 11: Removing Mounting Bolt From Pulley 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Unscrew mounting bolts -3- from coolant pump and carefully remove coolant pump -4- between engine 
bracket and toothed belt guard.  

Installing 

Installation is carried out in the reverse order of the removal procedure. Note the following during installation: 

z

Moisten new O-ring -3- with clean engine coolant.  

z

Insert coolant pump -4- into engine block and tighten mounting bolts -5- to 15 N.m (11 ft lb). 

z

Install pulley -2- and tighten mounting bolt -1- (replace). Tightening torque: 40 N.m (30 ft lb) plus 
additional 90° (1/4 turn).  

z

Install and tighten toothed belt. See TOOTHED BELTS, REMOVING, INSTALLING, 
TENSIONING
 .  

z

Install fuel filter with bracket.  

z

Disconnect fuel supply and return lines at fuel filter.  

z

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

NOTE:

Coolant pump plug points downward.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Install connecting hose between charge air cooler and intake hose. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
 .  

z

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

THERMOSTAT, REMOVING AND INSTALLING 

Special tools and equipment 

z

VAG 1306 Drip tray for VAG1202A  

z

VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

z

VAG 1921 Hose clip pliers  

z

Anti-freeze tester 

Fig. 12: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

z

Remove coolant hose from connection -2-  

z

Unscrew mounting bolts -1- of connection -2- and remove connection -2- along with thermostat -4-.  

z

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

NOTE:

Always replace seals and gaskets.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  917  918  919  920   ..