Volkswagen New Beetle. Manual - part 922

 

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Volkswagen New Beetle. Manual - part 922

 

 

Fig. 4: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Draining 

z

Remove cap from coolant expansion tank.  

z

Remove center and left side sound insulation: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

z

Remove drain plug (arrow) from radiator to drain. 

Fig. 5: Removing Drain Plug From Radiator To Drain 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

WARNING:

Steam can be released when the cap is removed from the expansion tank. 
Cover cap with a cloth and open carefully.

 

2003 Volkswagen New Beetle GLS 

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

  

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To drain coolant from engine, remove forward coolant hose from oil cooler (arrow). 

Fig. 6: Removing Forward Coolant Hose From Oil Cooler 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Filling 

z

Only use coolant additive G12 in accordance with TL VW 774 F. Distinguishing features: lilac (purple) 
color  

z

G12 lilac (according to TL VW 774 F) can be mixed with coolant additive G12 red.  

z

G12 and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion 
damage, scaling and raise the boiling point of coolant. For this reason the system must be filled all year 
round with frost and corrosion protection additives.  

z

Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly 
in countries with tropical climates.  

z

Protection against frost must be assured to about -25 °C (in arctic climatic countries to about -35 °C).  

z

The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer 
countries. The anti-freeze ratio must be at least 40%.  

z

If for climatic reasons a higher frost protection is required, the amount of G12 can be increased, but only 
up to 60% (frost protection to about -40 °C), otherwise frost protection is reduced again and cooling 
effectiveness is also reduced.  

z

Refractometer T10007 is recommended to determine coolant freezing temperature. 

NOTE:

Observe disposal regulations!

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 7: Identifying Special Tool (Refractometer T10007) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.  

Recommended mixture proportions: 

RECOMMENDED COOLANT MIXTURE PROPORTIONS 

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Screw drain plug into radiator.  

z

Push coolant hose onto oil cooler connection and secure with a spring-type clamp.  

With charging unit VAS 6096 

z

Fill coolant system using coolant system charging unit VAS 6096. 

Refer to instruction manual for coolant system charging unit VAS 6096

Anti-freeze to

Anti-freeze proportion

G12

(1)

Water

(1)

 , 

(2)

-25 °C

40%

2.4 liter

3.6 liter

-35 °C

50%

3.0 liter

3.0 liter

(1)

The quantity of coolant can vary in dependence on the vehicle equipment.

(2)

Use only clean drinking water.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 8: Pushing Coolant Hose Onto Oil Cooler Connection 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Without charging unit VAS 6096 

z

Fill coolant slowly up to upper hatched field mark (arrow) on expansion tank. 

Fig. 9: Filling Coolant Up To Upper Hatched Field Mark On Expansion Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Close expansion tank.  

z

Run engine until coolant fan cuts-in.  

z

Check coolant level and replenish if necessary. 

When engine is at normal operating temperature coolant level must lie on upper marking of hatched field 
(arrow). 

When engine is cold coolant level must lie approx. in middle of hatched field. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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