Volkswagen New Beetle. Manual - part 926

 

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Volkswagen New Beetle. Manual - part 926

 

 

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

7. Retaining clip 

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Check if seated securely  

8. 10 N.m  

9. To bottom of expansion tank 

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Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

10. To top of radiator 

z

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

11. O-ring 

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Replace  

12. Connecting unions  

13. To bottom of radiator 

z

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

14. Oil cooler 

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Removing and installing, See PART II (OIL FILTER HOUSING, DISASSEMBLING AND 
ASSEMBLING)
 .  

15. 15 N.m  

16. Coolant thermostat 

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Checking: Heat up thermostat in water  

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Starts to open: approx. 86°C  

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Opening stroke: min. 7 mm  

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Removing and installing, See THERMOSTAT, REMOVING AND INSTALLING  

17. Toothed belt 

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Mark direction of rotation before removing  

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Check for wear  

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Do not kink  

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Removing, installing and tensioning. See TOOTHED BELTS, REMOVING, INSTALLING 
AND TENSIONING
 .  

18. Coolant pump 

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Check for ease of movement  

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If damaged or leaking replace complete  

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Removing and installing, See COOLANT PUMP, REMOVING AND INSTALLING  

19. Rear toothed belt guard  

20. 20 N.m  

21. Throttle valve control module 

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Heated by coolant  

z

Coolant hose connection diagram, See COOLANT HOSE CONNECTION DIAGRAM  

22. To top of expansion tank 

 

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  

23. O-ring 

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Replace if damaged  

Fig. 3: Exploded View Of Engine Side Cooling System Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLANT HOSE CONNECTION DIAGRAM 

Engine code AEG (up to Model Year 1998) 

1. Radiator  

2. Oil cooler  

3. Coolant pump/coolant thermostat  

4. Cylinder head/cylinder block  

5. Expansion tank  

6. Intake manifold  

7. Throttle valve control module  

8. Union  

9. Heating system heat exchanger  

10. Coolant pipe  

11. ATF cooler 

z

Only models with an automatic transmission 

NOTE:

Engine codes AEG (from Model Year 1999), AVH, AZG, BDC, BEV, BGD, see 
ENGINE CODES AEG (FROM MODEL YEAR 1999), AVH, AZG, BDC, BEV, BGD .

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 4: Coolant Hose Connection Diagram (Engine Code AEG Up To Model Year 1998) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes AEG (from Model Year 1999), AVH, AZG, BDC, BEV, BGD 

1. Radiator  

2. Oil cooler  

3. Coolant pump/coolant thermostat  

4. Cylinder head/cylinder block  

5. Expansion tank  

6. Intake manifold  

7. Throttle valve control module  

8. Connecting unions  

9. Heating system heat exchanger  

10. Quick-action coupling  

11. Coolant pipe  

12. ATF cooler 

z

Only models with an automatic transmission 

NOTE:

The following list refers to items in Fig. 5 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 5: Coolant Hose Connection Diagram (Engine Codes AEG From Model Year 1999, AVH, AZG, 
BDC, BEV, BGD)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

COOLING SYSTEM, DRAINING AND FILLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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T10007 Refractometer  

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V.A.G 1306 Drip tray  

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Torque wrench VAG 1331  

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VAS 5024 Assembly tool for spring-type clamps  

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Adapter for expansion tank VAG 1274/8  

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VAS 6096 Coolant system charging unit 

Fig. 6: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Draining 

 

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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