Volkswagen New Beetle. Manual - part 955

 

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Volkswagen New Beetle. Manual - part 955

 

 

Coolant Capacity

(1)

 5.3 Qts. (5.0L)

Coolant Replacement Interval

(2)

Recommended Coolant

Golf & Jetta 

(3)

 , 

(5)

(4)

 Red G 012 A8 D

New Beetle

(5)

 Lilac (Purple) G 012 A8 F

Cooling Fan Thermal Switch

First Stage

On

198-207° F (92-97° C)

Off

183-196°F (84-91°C)

Second Stage

On

210-221°F (99-105°C)

Off

196-208°F (91-98°C)

Thermostat

Starts To Open

186°F (87°C)

Fully Open

216°F (102°C)

Opening Stroke

.28" (7 mm)

(1)

Total coolant quantity may vary depending on vehicle equipment.

(2)

Manufacturer does not require routine coolant replacement. Replace coolant only if major repair is 
necessary.

(3)

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
 .

(4)

G12 coolant is Red in color. DO NOT mix Green and Red coolant. Mixing these coolant types will 
cause severe engine damage.

(5)

G12 coolant is Lilac (Purple) in color. DO NOT mix Green with Lilac coolant. Mixing these coolant 
types will cause severe engine damage.

 

2003 Volkswagen New Beetle GLS 

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

Engine Code)

  

1998-04 ENGINE COOLING 

Electric Cooling Fans - Beetle 

DESCRIPTION & OPERATION 

ELECTRIC COOLING FAN 

1.8L Turbo 

Electric cooling fan operation is controlled through input from the following devices:  

z

Coolant fan control thermo switch  

z

Coolant fan control module  

z

Ambient temperature switch  

z

A/C high pressure sensor  

z

Third speed coolant fan control relay  

1.9L TDI & 2.0L 

Electric cooling fan operation is controlled through input from a coolant fan control thermo switch, coolant fan 
control module, and the A/C high pressure sensor or switch.  

A/C CUT-OUT THERMAL SWITCH 

1.8L Turbo 

The A/C cut-out thermal switch turns A/C clutch off when coolant temperature is excessively high. A/C cutout 
thermal switch turns A/C clutch off at 246°F (119°C) and turns A/C clutch back on at 234°F (112°C). This 
switch also controls the operation of the third speed coolant fan control relay with 1.8L engine.  

A/C HIGH PRESSURE SENSOR 

The A/C high pressure sensor supplies a refrigerant system pressure signal to the coolant fan control module. 
Depending on year and engine application, this signal may also monitored by the ECM.  

The A/C high pressure sensor transmits a square wave signal to coolant fan control module at a rate which 
varies according to the refrigerant system pressure. If the refrigerant system pressure rises, the sensor switches 
the radiator fan(s) to the second (high) speed. This sensor is also used to control A/C clutch engagement.  

A/C HIGH PRESSURE SWITCH 

NOTE:

The vehicle may be equipped with either a A/C high pressure sensor or a A/C 
high pressure switch. 

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:37:31 AM

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Helpmelearn Repair Manuals 

 

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Some models may be equipped with an A/C pressure switch. This is a 4-wire switch located in the A/C high 
pressure line. This switch has 2 functions. It switches off the A/C compressor clutch when A/C high side 
pressure is excessive or too low. It also switches the coolant fan to the next higher speed when pressure 
increases in the refrigerant circuit.  

COOLANT FAN CONTROL THERMO SWITCH 

The coolant fan control thermo switch is mounted in the radiator. It controls coolant fan operation based on 
coolant temperature.  

COMPONENT LOCATIONS 

COMPONENT LOCATIONS 

NOTE:

The vehicle may be equipped with either a A/C high pressure sensor or a A/C 
high pressure switch. 

Component 

(1)

Location 

A/C High Pressure Sensor 

Right Rear Corner Of Engine Compartment 

A/C High Pressure Switch 

Right Rear Corner Of Engine Compartment 

A/C Thermal Cut-Out Switch (1.8L 
Turbo) 

In Coolant Flange, Rear Of Cylinder Head 

Ambient Temperature Switch 

Right Side Fresh Air Intake, Below Water 

Deflector 

Coolant Fan Control Module 

Left Front Corner Of Engine Compartment 

Coolant Fan Control Thermo Switch 

In Lower Left Corner Of Radiator 

Coolant Fan Ground Point 

Left Front Of Engine Compartment 

Third Speed Coolant Fan Control 
Relay (1.8L Turbo) 

Thirteen-Way Relay Panel, Under Driver's Side 

Of Dash (Position No. 10) 

(1)

See Fig. 1 -Fig. 3 for component locations.

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:37:31 AM

Page 2 

© 2004 Mitchell Repair Information Company, LLC. 

 

2003 Volkswagen New Beetle GLS 

1998-04 ENGINE COOLING Electric Cooling Fans - Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:37:31 AM

Page 3 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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