Volkswagen New Beetle. Manual - part 924

 

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Volkswagen New Beetle. Manual - part 924

 

 

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Drain coolant. See COOLANT, DRAINING AND FILLING .  

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Remove coolant hose from pipe union.  

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Remove securing bolts -1- of pipe union -2- and remove pipe union -2- with thermostat -4-.  

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

Fig. 15: Removing Pipe Union With Thermostat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

Installation is performed in reverse order. Note the following: 

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Coat new O-ring -3- with coolant and install to pipe union -2-.  

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Insert thermostat -4- into pipe union -2- and turn 1/4 (90°) to right. 

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 16: Installing Connecting Union With Thermostat
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Install connecting union -2- with thermostat -4- into engine block.  

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Tighten securing bolts -1-. 

Tightening torque: 15 N.m 

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Fill with coolant. See COOLANT, DRAINING AND FILLING .  

GLOW PLUGS, CHECKING 

Special tools and equipment 

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V.A.G 1594 A Adapter set 

Fig. 17: Identifying Special Tools And Equipment (V.A.G 1594 Adapter Set) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1527 B Diode test lamp 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 18: Identifying Special Tools And Equipment (V.A.G 1527 B Diode Test Lamp) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Battery voltage at least 11.5 V  

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Ignition switched off  

Work sequence 

Checking electric activation of glow plugs: 

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Disconnect connector -1- from glow plugs.  

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Connect diode test lamp cable with clamps from adapter set to battery positive (+).  

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Insert diode test lamp test pick to every glow plug one after another. 

Fig. 19: Using Diode Test Lamp To Check Glow Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Diode lights up: glow plug is OK 

Diode does not light up: 

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Replace glow plug. See GLOW PLUGS, CHECKING 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  922  923  924  925   ..