Volkswagen New Beetle. Manual - part 936

 

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Volkswagen New Beetle. Manual - part 936

 

 

Fig. 6: Identifying Cooling System Components & Coolant Flow (1.8L Turbo APH, AWP M/T & AWV - 
New Beetle)
 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

DRAINING, FILLING & BLEEDING

COOLING SYSTEM PRECAUTIONS 

Use only coolant additive G12 meeting specification VW 774 D. G12 coolant is Red in color. G12 must not be 
mixed with any other additives. If fluid in expansion tank is Brown, this is an indication that G12 has been 
mixed with another type of coolant. In this case, coolant must be changed. 

G12 coolant additive may be used in older vehicles when original coolant is drained and cooling system is 
flushed. Contaminated coolant must be drained immediately and cooling system flushed. See SERVICING . 
Also, if radiator, heat exchanger (heater core), cylinder head or cylinder head gasket, have been replaced, flush 
cooling system and replace engine coolant. 

DRAINING, FILLING & BLEEDING COOLING SYSTEM 

1.8L Turbo 

1. Turn engine off, and allow to cool. Raise and support vehicle. Remove noise insulation panel, below 

engine. See Fig. 7 , Fig. 8 or Fig. 9 . Open expansion tank cap.  

2. Place appropriate drain pan underneath vehicle. Unscrew drain screw on radiator, and drain coolant. See 

Fig. 10 . Remove lower coolant hose clamp, and drain coolant from engine. See Fig. 11 .  

3. Turn radiator drain screw closed, and tighten. Push coolant hose onto oil cooler, and tighten hose clamp. 

4. Slowly fill expansion tank, to upper marking of shaded area, with recommended coolant mixture. See 

Fig. 12 . See COOLING SYSTEM SPECIFICATIONS .  

5. Install expansion tank cap. Turn off A/C and heat controls. Start engine, and raise engine speed to 2000 

RPM for approximately 3 minutes. Allow engine to idle, until coolant fan turns on. Check coolant level, 
and top off as necessary.  

6. When engine is at normal operating temperature, coolant level must be at upper marking of shaded area, 

on expansion tank. When engine is cold, coolant level should be at approximately middle of shaded area. 
See Fig. 12 .  

WARNING:

Cooling system is pressurized, when engine is at operating temperature. 
Use caution and use other appropriate protective gear when servicing 
cooling system. Slowly and carefully release system pressure, before 
performing any repairs.

NOTE:

See COOLING SYSTEM PRECAUTIONS before beginning cooling system 
servicing.

CAUTION: DO NOT mix Green and Red coolant. Mixing these two coolant types 

will cause severe engine damage. Use ONLY G 012 A8 D Red coolant. 
See COOLING SYSTEM SPECIFICATIONS .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 7: Identifying Noise Insulation Mounting Points (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)

  

Fig. 8: Identifying Noise Insulation Mounting Points (New Beetle) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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