Volkswagen New Beetle. Manual - part 934

 

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Volkswagen New Beetle. Manual - part 934

 

 

z

Install connecting hose between charge air cooler and intake hose. See CHARGE AIR COOLER 
COMPONENTS, REMOVING AND INSTALLING
 .  

z

Fill engine with coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

THERMOSTAT, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1306 Drip tray for VAG1202A  

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VAG 1331 Torque wrench: 5 to 50 N.m (3.7 to 37 ft lb)  

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VAG 1921 Hose clip pliers  

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Anti-freeze tester 

Fig. 12: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Remove coolant hose from connection -2-  

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Unscrew mounting bolts -1- of connection -2- and remove connection -2- along with thermostat -4-.  

z

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

NOTE:

Always replace seals and gaskets.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Removing Thermostat 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

 

2003 Volkswagen New Beetle GLS 

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

  

Installation is carried out in the reverse order. Note the following during installation: 

z

Moisten new O-ring -3- with coolant.  

z

Insert thermostat -4- in connection -2- and turn 1/4 turn (90°) to right. 

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Install thermostat -4- into engine block.  

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Tighten mounting bolt -1- to 15 N.m (11 ft lb).  

z

Fill engine with coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

NOTE:

The brace on the thermostat must be almost vertical.

 

2003 Volkswagen New Beetle GLS 

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

  

2002-04 ENGINE COOLING

Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat) 

ENGINE IDENTIFICATION 

Information in this article applies to the 1.8L turbo engine for engine codes AWD, AWP, AWW and AWV. 

Engine identification an be found on front joint (machined surface) between engine and transmission. See Fig. 1
or Fig. 2 . Also engine code is listed on vehicle data plate. Additionally, there is a sticker on timing belt guard 
with engine code and serial number. See Fig. 3 . 

Fig. 1: Locating Engine Code On Machined Surface (1.8L Turbo AWD Engine Code Shown; AWP & 
AWW Similar - Golf, GTI & Jetta)
 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

  

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

  

 

 

 

 

 

 

 

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