Volkswagen New Beetle. Manual - part 923

 

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Volkswagen New Beetle. Manual - part 923

 

 

RADIATOR, REMOVING AND INSTALLING

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray for VAG1202A  

z

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

z

VAS 5024 Assembly tool for spring-type clips 

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

Removing 

z

Drain coolant. See COOLANT, DRAINING AND FILLING .  

z

Remove front end: 

See FRONT END, ASSEMBLY OVERVIEW . 

z

Remove coolant hoses from radiator.  

z

Remove connectors from thermal switch and coolant fan.  

z

Remove lock carrier: 

See LOCK CARRIER, ASSEMBLY OVERVIEW 

z

Remove radiator securing bolts and take out radiator. 

NOTE:

Models with air conditioning system: 

z

Observe additional information and removal work. See ADDITIONAL 
INFORMATION AND ASSEMBLY WORK ON MODELS WITH AN A/C 

 

2003 Volkswagen New Beetle GLS 

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

  

Installing 

Installation is performed in reverse order. Note the following: 

z

Fill with coolant. See COOLANT, DRAINING AND FILLING .  

Additional information and assembly work on models with an A/C system 

z

Release refrigerant lines/hoses from retainers/clamps if necessary.  

z

Secure radiator to body before removing lock carrier.  

z

To remove radiator, secure condenser to body.  

COOLANT PUMP, REMOVING AND INSTALLING 

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray for VAG1202A  

z

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

z

VAS 5024 Assembly tool for spring-type clips 

Fig. 11: Special Tools And Equipment (Coolant Pump)  
Courtesy of VOLKSWAGEN OF AMERICA, INC.

SYSTEM .  

CAUTION: The air conditioning system refrigerant circuit must not be opened.

NOTE:

To prevent damage to the condenser as well as to the refrigerant lines, ensure 
that lines and hoses are not stretched, kinked or bent.

 

2003 Volkswagen New Beetle GLS 

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

  

Removing 

z

Drain coolant. See COOLANT, DRAINING AND FILLING .  

z

Remove toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

z

Remove coolant pump securing bolts -1- and remove coolant pump -2- carefully. 

Fig. 12: Removing Coolant Pump And Securing Bolts 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in reverse order. Note the following: 

z

Clean or smooth sealing surface for O-ring.  

z

Moisten new O-ring -3- with coolant.  

z

Insert coolant pump -2- into cylinder block and tighten securing bolts -1-. 

Tightening torque: 15 N.m 

z

Install toothed (timing) belt. See TOOTHED BELT, REMOVING AND INSTALLING .  

z

Fill with coolant. See COOLANT, DRAINING AND FILLING 

NOTE:

Always replace seals and gaskets.

NOTE:

The coolant pump plug faces downward.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Identifying Coolant Pump And Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

THERMOSTAT, REMOVING AND INSTALLING 

Special tools and equipment 

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray  

z

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

z

VAS 5024 Assembly tool for spring-type clips 

Fig. 14: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

NOTE:

z

Always replace seals and gaskets. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  921  922  923  924   ..