Volkswagen New Beetle. Manual - part 925

 

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Volkswagen New Beetle. Manual - part 925

 

 

1998-2004 ENGINE

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

COOLING SYSTEM, SERVICING 

COOLING SYSTEM, GENERAL INFORMATION 

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and 

WARNING:

When performing repair work, especially due to the confined conditions 
in the engine compartment, pay attention to the following: 

z

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

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Ensure sufficient clearance to all moving or hot components.  

NOTE:

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When the engine is warm the cooling system is under pressure. If 
necessary release the pressure before beginning repair work.  

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Hoses are secured with spring-type clamps. In cases of repair only use 
spring-type clamps.  

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Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended 
for installing spring-type clamps. 

Fig. 1: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

V.A.G 1274/9. 

Components of cooling system body side, See COOLING SYSTEM COMPONENTS - BODY SIDE, 
REMOVING AND INSTALLING
 . 

Components of cooling system engine side, See COOLING SYSTEM COMPONENTS - ENGINE SIDE, 
REMOVING AND INSTALLING
 . 

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM 

Draining and filling with coolant, See COOLING SYSTEM, DRAINING AND FILLING . 

Coolant mixing ratios, See COOLING SYSTEM, DRAINING AND FILLING 

COOLING SYSTEM COMPONENTS - BODY SIDE, REMOVING AND INSTALLING 

1. Radiator 

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Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

z

After replacement replace entire coolant amount  

2. O-ring 

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Replace  

3. Upper coolant hose 

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Secured to radiator with retaining clip  

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

4. 4 N.m  

5. Cover 

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Check with cooling system tester V.A.G1274 and adapter V.A.G 1274/9  

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Pressure relief valve must open at a pressure of 1.4...1.6 bar  

6. 2 N.m  

7. Expansion tank 

z

Perform leak test on cooling system with cooling system tester V.A.G 1274 and adapter 
V.A.G1274/8  

z

Test pressure 1.4...1.6 bar  

z

Observe markings, See COOLING SYSTEM, DRAINING AND FILLING  

8. Connector  

9. To coolant pipe 

NOTE:

Coolant hose connection diagram, See COOLANT HOSE CONNECTION 
DIAGRAM

NOTE:

The following list refers to items in Fig. 2 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

10. Air ducting  

11. 10 N.m  

12. Right coolant fan -V35- 

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Only models with optional equipment  

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Checking, See COOLANT FAN, CHECKING  

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Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

13. Fan ring 

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For right coolant fan  

14. Retaining clip 

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Check if seated securely  

15. Fan ring  

16. Coolant fan - V7- 

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Checking, See COOLANT FAN, CHECKING  

z

Removing and installing, See RADIATOR, REMOVING AND INSTALLING  

17. Retainer 

z

For coolant fan connector  

18. Lower coolant hose 

z

Secured to radiator with retaining clip  

z

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

z

Check if seated securely  

19. Coolant Fan Control (FC) thermal switch -F18-, 35 N.m 

z

For electric fan  

z

Switching temperatures: 1. stage on: 92...97°C, off: 84...91°C; 2. stage on: 99...105 C, off: 91...98°
C  

20. Retainer 

z

For bottom of radiator  

21. Retainer 

z

For top of radiator  

z

Observe installed position  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 2: Exploded View Of Body Side Cooling System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM COMPONENTS -ENGINE SIDE, REMOVING AND INSTALLING 

1. Heating system heat exchanger  

2. Connector 

z

4-pin  

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Gold plated contacts for ECT sensor - G62-  

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

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For engine control module  

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With ECT sensor -G2-  

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Gold plated contacts for ECT sensor -G62-  

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Release pressure in cooling system if necessary before removing components  

4. Connector 

z

2-pin  

z

Only for engine code AEG until Model Year 1999  

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Only vehicles with air conditioner with 4-pin A/C Pressure Switch -F129-  

5. A/C cut-out thermal switch -F163- 

z

Only for engine code AEG until Model Year 1999  

z

Only vehicles with air conditioner with 4-pin A/C Pressure Switch -F129-  

z

Vehicles with air conditioner only, otherwise blind plug  

6. Coolant pipe 

NOTE:

Coolant hose connection diagram, See COOLANT HOSE CONNECTION 
DIAGRAM

NOTE:

The following list refers to items in Fig. 3 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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