Volkswagen New Beetle. Manual - part 964

 

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Volkswagen New Beetle. Manual - part 964

 

 

When engine is cold coolant level should be around middle of hatched field. 

Filling coolant system with charging unit VAS 6096 

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Screw adapter V.A.G1274/8 onto expansion tank.  

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Fill coolant system using coolant system charging unit VAS 6096: 

See Instruction manual for coolant system charging unit VAS 6096 

RADIATOR, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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T10007 Refractometer  

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V.A.G 1306 Drip tray  

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V.A.G 1331 Torque wrench (5...50 N.m)  

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VAS 5024 Assembly tool for spring-type clamps 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

Fig. 15: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Drain coolant, See COOLING SYSTEM, DRAINING AND FILLING  

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Pull connectors off thermal switch -1- and coolant fan -2-. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

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Remove front end: 

See FRONT END, ASSEMBLY OVERVIEW . 

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Remove lock carrier: 

See LOCK CARRIER, ASSEMBLY OVERVIEW . 

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Pull coolant hoses quick release couplings off radiator. 

Fig. 16: Disconnecting Thermal Switch And Coolant Fan Connectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Models with air conditioning 

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Observe additional information and removal work, See Additional information and assembly work on 
models with an air conditioning system
 .  

Continuation for all models 

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Remove radiator securing bolts and take out radiator.  

Installing 

Install in reverse sequence. Note the following points:

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

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Check electrical connections and routing: 

See appropriate SYSTEM WIRING DIAGRAMS article 

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Refill with coolant, See COOLING SYSTEM, DRAINING AND FILLING .  

Additional information and assembly work on models with an air conditioning system 

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Remove retaining clamp(s) from refrigerant lines.  

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Secure radiator to body before removing lock carrier.  

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Remove condenser from radiator and secure to lock carrier.  

COOLANT FAN, CHECKING 

Engine codes AEG, AVH, AZG 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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V.A.G 1594 Adapter set  

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Wiring diagram 

CAUTION: The air conditioning refrigerant circuit must not be opened.

NOTE:

To prevent damage to the condenser as well as to the refrigerant lines/hoses, 
ensure that the lines and hoses are not stretched, kinked or bent.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Cooling System - New Beetle, 2.0L (AEG, AVH, AXG, BDC BEV & BGD)

  

 

 

 

 

 

 

 

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