Volkswagen New Beetle. Manual - part 949

 

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Volkswagen New Beetle. Manual - part 949

 

 

Fig. 7: Locating Oil Cooler Hoses 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

4. Close drain plug at radiator. Fill cooling system with recommended coolant mixture. See COOLING 

SYSTEM SPECIFICATIONS . Fill expansion tank with coolant to MAX mark. Install expansion tank 
cap.  

5. Start engine, and let 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 on MAX mark, on expansion 

tank. See Fig. 8 . When engine is cold, coolant level must be between MIN and MAX marks, on 
expansion tank. 

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 - 1.9L TDI (ALH Engine Code)

  

Fig. 8: Identifying Expansion Tank Markings 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

SERVICING 

Coolant does not usually need replacing. In cases of larger repairs when coolant needs to be drained, new 
coolant must be used because old coolant has been exposed to oxidation and dirt. Flush cooling system when 
replacing coolant. To flush, fill system with clear water, and run engine for approximately 2 minutes. Flushing 
system should remove most coolant residue. Fill with a mix of clean water and manufacturer recommended 
coolant. See COOLING SYSTEM SPECIFICATIONS . 

Coolant to water ratio must not exceed 60%. Frost protection and cooling efficiency will decrease if the 
percentage of coolant is too high. For coolant to water ratio, see COOLANT MIXTURE 
RECOMMENDATIONS
 table under COOLING SYSTEM SPECIFICATIONS. 

ADJUSTMENTS 

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

  

Prior to removing drive belt, mark direction of rotation. Serpentine belt is self-adjusting. For proper belt 
routing, see DRIVE BELT ROUTING . 

DRIVE BELT ROUTING 

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

  

Fig. 9: Drive Belt Routing (With A/C) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

  

 

 

 

 

 

 

 

Content   ..  947  948  949  950   ..