Volkswagen New Beetle. Manual - part 952

 

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Volkswagen New Beetle. Manual - part 952

 

 

1. Turn engine off, and allow to cool. Open cap on coolant expansion tank. Raise and support vehicle. 

Remove noise insulation panel from below engine compartment. See Fig. 5 . 

Fig. 5: Identifying Noise Insulation Mounting Points

system pressure, before performing any repairs.

CAUTION: On model year 2004 Golf and Jetta, engine code BEV, uses G12 coolant 

that is Lilac (Purple) in color. Refer to TSB Group 19 No. 02-01, dated Dec. 
20, 2002. See COOLANT (ANTIFREEZE), MIXING PRECAUTIONS .

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

Courtesy of VOLKSWAGEN UNITED STATES, INC.

2. Unscrew drain plug (arrow), and drain coolant from radiator. See Fig. 6 . Remove coolant hose from oil 

cooler (arrow). See Fig. 7 . Drain coolant from engine. 

Fig. 6: Identifying Drain Screw On Radiator 
Courtesy of AUDI OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

Fig. 7: Removing Oil Cooler Coolant Hose 
Courtesy of AUDI OF AMERICA, INC. 

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

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 .

CAUTION: On model year 2004 Golf and Jetta, engine code BEV, uses G12 

coolant that is Lilac (Purple) in color. Refer to TSB Group 19 No. 02-
01, dated Dec. 20, 2002. See COOLANT (ANTIFREEZE), MIXING 
PRECAUTIONS .

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

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

4. If VAS 6096 Charging Unit is available, close drain plug at radiator. Connect oil cooler hoses. Fill 

cooling system according to VAS 6096 Charging Unit instruction manual. Fill cooling system with 
recommended coolant mixture. See COOLING SYSTEM SPECIFICATIONS . If VAS 6096 Charging 
Unit is not available, close drain plug at radiator. Connect oil cooler hoses. Fill cooling system with 
recommended coolant mixture. See COOLING SYSTEM SPECIFICATIONS . Slowly fill expansion 
tank with coolant to upper hatch mark. See Fig. 8 . Install expansion tank cap.  

5. 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. 
Turn ignition off.  

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. 8 .  

 

2003 Volkswagen New Beetle GLS 

2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD 

Engine Code)

  

 

 

 

 

 

 

 

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