Volkswagen New Beetle. Manual - part 927

 

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Volkswagen New Beetle. Manual - part 927

 

 

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Open cap on coolant expansion tank.  

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Remove sound insulation tray: 

See NOISE INSULATION, ASSEMBLY OVERVIEW . 

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Place drip tray VAG 1306 under vehicle.  

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Remove drain plug (arrow) to drain coolant from radiator. 

Fig. 7: Removing Radiator Drain Plug 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove coolant hose from oil cooler (arrow) to drain coolant from engine. 

WARNING:

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

NOTE:

Observe waste disposal regulations!

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 8: Removing Coolant Hose From Oil Cooler 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Filling 

NOTE:

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Only use coolant additive G 12 in accordance with TL VW 774 F. 
Distinguishing color: violet  

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G 12 and coolant additives marked "In accordance with TL VW 774 F" 
prevent frost and corrosion damage, scaling and also raise boiling point of 
coolant. For this reason the system must be filled all year round with frost 
and corrosion protection additives.  

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G 12 (according to TL VW 774 F) can be mixed with coolant additive G12 
which is colored red.  

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

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

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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%.  

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If for climatic reasons a higher anti-freeze is required, the amount of G 12 
can be increased, but only up to 60% (anti-freeze to about -40° C), as 
otherwise antifreeze is reduced again and cooling effectiveness is also 
reduced.  

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Refractometer T 10007 is recommended to determine coolant freezing 
temperature. 

 

2003 Volkswagen New Beetle GLS 

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

  

Recommended mixture ratios: 

RECOMMENDED MIXTURE RATIOS SPECIFICATIONS 

Work sequence 

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Screw drain plug into radiator.  

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

Fig. 9: Identifying Refractometer T 10007 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

Antifreeze to

Anti-freeze proportion

G 12

(1)

(1)

 , 

(2)

 Water

-25° C -

40%

2.0 I

3.0 I

-35° C

50%

2.5 I

2.5 I

(1)

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

(2)

Use only clean drinking water.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 10: Pushing Coolant Hose Onto Oil Cooler Connection And Securing With Spring-Type Clamp 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Vehicles with max. expansion tank marking 

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Fill with coolant up to max. mark on expansion tank. 

Fig. 11: Identifying Expansion Tank (Vehicles With Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Fit expansion tank cap.  

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Switch off heater and air conditioner.  

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Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes.  

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Run engine until coolant fan starts.  

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Switch off ignition. 

WARNING:

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

 

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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