Volkswagen New Beetle. Manual - part 928

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  926  927  928  929   ..

 

 

Volkswagen New Beetle. Manual - part 928

 

 

z

Check coolant level and top up if necessary. 

When engine is at normal operating temperature, coolant level must be on max. mark. 

Fig. 12: Identifying Expansion Tank (Vehicles With Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

When engine is cold coolant level must be between min. and max. marks. 

Vehicles without max. expansion tank marking 

z

Fill coolant slowly up to upper hatched field mark (arrow) on expansion tank. 

Fig. 13: Identifying Expansion Tank (Vehicles Without Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Close expansion tank.  

z

Switch off heater and air conditioner.  

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

z

Run engine until coolant fan starts.  

z

Switch off ignition. 

z

Check coolant level and top up if necessary: 

Coolant level must be at upper hatched field mark when engine is at operating temperature (arrow). 

Fig. 14: Identifying Expansion Tank (Vehicles Without Max. Tank Marking) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

When engine is cold coolant level should be around middle of hatched field. 

Filling coolant system with charging unit VAS 6096 

z

Screw adapter V.A.G1274/8 onto expansion tank.  

z

Fill coolant system using coolant system charging unit VAS 6096: 

See Instruction manual for coolant system charging unit VAS 6096 

RADIATOR, REMOVING AND INSTALLING 

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

z

T10007 Refractometer  

z

V.A.G 1306 Drip tray  

z

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

z

VAS 5024 Assembly tool for spring-type clamps 

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)

  

Fig. 15: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Drain coolant, See COOLING SYSTEM, DRAINING AND FILLING  

z

Pull connectors off thermal switch -1- and coolant fan -2-.  

z

Remove front end: 

See FRONT END, ASSEMBLY OVERVIEW . 

z

Remove lock carrier: 

See LOCK CARRIER, ASSEMBLY OVERVIEW . 

z

Pull coolant hoses quick release couplings off radiator. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 16: Disconnecting Thermal Switch And Coolant Fan Connectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Models with air conditioning 

z

Observe additional information and removal work, See Additional information and assembly work on 
models with an air conditioning system
 .  

Continuation for all models 

z

Remove radiator securing bolts and take out radiator.  

Installing 

Install in reverse sequence. Note the following points: 

z

Check electrical connections and routing: 

See appropriate SYSTEM WIRING DIAGRAMS article 

z

Refill with coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

Additional information and assembly work on models with an air conditioning system 

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

NOTE:

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

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  926  927  928  929   ..