2003 Volkswagen New Beetle GLS

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

2002-04 ENGINE COOLING

Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

ENGINE IDENTIFICATION
Information in this article applies to the 1.8L turbo engine for engine codes AWD, AWP, AWW and AWV.

Engine identification an be found on front joint (machined surface) between engine and transmission. See Fig. 1
or Fig. 2 . Also engine code is listed on vehicle data plate. Additionally, there is a sticker on timing belt guard
with engine code and serial number. See Fig. 3 .

Fig. 1: Locating Engine Code On Machined Surface (1.8L Turbo AWD Engine Code Shown; AWP &
AWW Similar - Golf, GTI & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 2: Locating Engine Code On Machined Surface (1.8L Turbo Engine Code APH Shown, AWP &
AWV Similar - New Beetle)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:01:55 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 3: Locating Engine Code On Timing Belt Guard (1.8L Turbo Engine Code AWP & AWW - Golf,
GTI & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

COMPONENT LOCATIONS
COOLING SYSTEM IDENTIFICATION

NOTE: Three letter code indicates engine identification code. For location of engine
code, see ENGINE IDENTIFICATION .

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December-27-07 12:01:56 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 4: Identifying Cooling System Components & Coolant Flow (1.8L Turbo AWP M/T & AWW M/T &
A/T - Golf, GTI & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:01:56 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 5: Identifying Cooling System Components & Coolant Flow (1.8L Turbo AWP A/T Only - Golf, GTI
& Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:01:56 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

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

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December-27-07 12:01:56 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
 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

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.

1.8L Turbo

NOTE: See COOLING SYSTEM PRECAUTIONS before beginning cooling system

servicing.

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.

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 .

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 .

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December-27-07 12:01:56 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
 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.

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December-27-07 12:01:56 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
 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.

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December-27-07 12:01:56 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 9: Identifying Noise Insulation Mounting Points (New Beetle Convertible)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 10: Identifying Drain Screw On Radiator

Courtesy of AUDI OF AMERICA, INC.

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December-27-07 12:01:56 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 11: Removing Lower Coolant Hose

Courtesy of AUDI OF AMERICA, INC.

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December-27-07 12:01:56 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 12: Identifying Expansion Tank Markings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

SERVICING

WARNING: Cooling system is pressurized, when engine is at operating temperature.

Wear gloves, and other appropriate protection. Slowly and carefully
release system pressure, before performing any repairs.

Coolant does not usually need replacing. In case of larger repairs when coolant needs to be drained, new coolant
must be used because, old 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. Drain cooling system. See
DRAINING, FILLING & BLEEDING . Flushing system should remove most coolant residue.

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.
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December-27-07 12:01:56 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

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

DRIVE BELT ROUTING

NOTE: Serpentine belt is self-adjusting. See Fig. 13 or Fig. 14 .

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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

Fig. 13: Drive Belt Routing (With A/C)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 14: Drive Belt Routing (Without A/C)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

COOLING SYSTEM SPECIFICATIONS

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December-27-07 12:01:56 PM Page 15 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.8L Turbo (Except Passat)

COOLANT MIXTURE RECOMMENDATIONS

Application Specification
Freeze Point
Down To -13° F (- 25° C) 40% Coolant
Down To -31° F (- 35° C) 50% Coolant

COOLING SYSTEM SPECIFICATIONS

Application Specification
Coolant Capacity (1) 5.2 Qts. (5.0L)
Coolant Replacement Interval (2)

Recommended Coolant Type (3) G 012 A8 D

Thermostat
Starts To Open 185°F (85°C)
Fully Open 220°F (105°C)
Opening Stroke .28" (7 mm)
(1) Total coolant quantity may vary depending on vehicle equipment.

(2) Manufacturer does not require routine coolant replacement. Coolant is only replaced during major
repairs.
(3) G12 coolant is Red in color. DO NOT mix Green and Red coolant. Mixing these two coolant types
will cause severe engine damage.

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December-27-07 12:01:56 PM Page 16 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

2002-04 ENGINE COOLING

Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

ENGINE IDENTIFICATION
Engine identification code is stamped between diesel injection pump and exhaust manifold, on cylinder block.
See Fig. 1 . In addition, engine code and serial number are on a sticker on timing belt cover. Also engine code is
listed on vehicle data plate.

Fig. 1: Locating Engine Identification Code (1.9L TDI, ALH)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

COMPONENT LOCATIONS
COOLING SYSTEM IDENTIFICATION

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12:02:47 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

NOTE: Three letter code indicates engine identification code. For location of engine
code, see ENGINE IDENTIFICATION .

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December-27-07 12:02:47 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

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December-27-07 12:02:47 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 2: Identifying Cooling System Component & Coolant Flow (1.9L TDI, Golf & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:02:47 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 3: Identifying Cooling System Components & Coolant Flow (1.9L TDI, Beetle)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

WARNING: Cooling system is pressurized, when engine is at operating temperature.

Use caution and use other appropriate protective gear (safety glasses and
gloves) when servicing cooling system. Slowly and carefully release
system pressure, before performing any repairs.

1.9L TDI (Engine Code ALH)

1. Turn engine off, and allow to cool. Remove engine cover. Open cap on coolant expansion tank. Raise and
support vehicle. Remove noise insulation panel from below engine compartment. See Fig. 4 or Fig. 5 .
Place appropriate drain pan underneath vehicle.

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December-27-07 12:02:47 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 4: Identifying Noise Insulation Mounting Points (Golf & Jetta)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:02:47 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 5: Identifying Noise Insulation Mounting Points (Beetle)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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December-27-07 12:02:47 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 6: Identifying Drain Screw On Radiator

Courtesy of AUDI OF AMERICA, INC.

3. Remove coolant hose from oil cooler, and drain coolant from engine. See Fig. 7 .

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December-27-07 12:02:47 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 7: Locating Oil Cooler Hoses

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 .

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.

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December-27-07 12:02:47 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
 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
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December-27-07 12:02:47 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.
 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

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December-27-07 12:02:47 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.
 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.

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December-27-07 12:02:47 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

Fig. 10: Drive Belt Routing (Without A/C)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

COOLING SYSTEM SPECIFICATIONS

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December-27-07 12:02:47 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 1.9L TDI (ALH Engine Code)

COOLANT MIXTURE RECOMMENDATIONS

Application Specification
Freezing Point
Down To -13° F (- 25° C) 40% Coolant
Down To -31° F (- 35° C) 50% Coolant

COOLING SYSTEM SPECIFICATIONS

Application Specification
Coolant Capacity (1) 6.3 Qts. (6.0L)
Coolant Replacement Interval (2)

Recommended Coolant (3) G 012 A8 D

Thermostat
Start To Open 185° F (85° C)
Fully Open 221° F (105° C)
Opening Lift 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) G12 coolant is Red in color. DO NOT mix Green and Red coolant. Mixing these two coolant types
will cause severe engine damage.

Helpmelearn
December-27-07 12:02:47 PM Page 14 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

2002-04 ENGINE COOLING

Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD Engine
Code)

ENGINE IDENTIFICATION
Engine identification is stamped on machined surface between engine and transmission. See 2.0L
ENGINE/MODEL IDENTIFICATION table. Additionally, there is a sticker, located on timing belt guard.
Engine code is also included on vehicle data plate.

2.0L ENGINE/MODEL IDENTIFICATION

Year Model (1) Engine Code
2002
Golf & Jetta AVH & AZG
New Beetle AEG, AVH/AZG
2003
Golf & Jetta AVH, AZG & BBW
New Beetle AVH/AZG
New Beetle Convertible BDC
2004
Golf & Jetta AVH, AZG, BBW & BEV
New Beetle BEV
New Beetle Convertible BGD
(1) See Fig. 1 , Fig. 2 or Fig. 3 .

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 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. 1: Locating Engine Code (AVH, AZG, BBW & BEV - Golf & Jetta)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:03:30 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
 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. 2: Locating Engine Code (AEG - New Beetle)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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December-27-07 12:03:30 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.
 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. 3: Locating Engine Code (AVH, AZG, BDC, BEV & BGD - New Beetle)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

COMPONENT LOCATIONS
COOLING SYSTEM IDENTIFICATION

NOTE: Three letter code indicates engine identification code. For location of engine
code, see ENGINE IDENTIFICATION .

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December-27-07 12:03:30 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

Helpmelearn
December-27-07 12:03:31 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.
 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. 4: Identifying Cooling System Components & Coolant Flow (AEG, AVH, AZG, BDC, BEV & BGD -
New Beetle)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

DRAINING, FILLING & BLEEDING

COOLING SYSTEM PRECAUTIONS

Golf & Jetta

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 .

For all except 2004 Golf and Jetta with BEV engine code, 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.

New Beetle

NOTE: Cooling system precautions reference to TSB Group 19 No. 02-01, dated Dec.
20, 2002. See COOLANT (ANTIFREEZE), MIXING PRECAUTIONS .

Use only coolant additive G 12 meeting specification VW 774 F. G 12 coolant is Lilac (Purple) in color. Red
coolant G12, meeting specification VW 774 D, can be mixed with G 12 Lilac coolant. G 12 must NOT be
mixed with any other additives. If fluid in expansion tank is Brown, this is an indication that G 12 has been
mixed with another type of coolant. In this case, coolant must be changed.

G 12 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

Golf & Jetta

WARNING: Cooling system is pressurized, when engine is at operating temperature.

Use caution and use other appropriate protective gear (safety glasses and
gloves) when servicing cooling system. Slowly and carefully release
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December-27-07 12:03:31 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.
 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

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 .

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

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December-27-07 12:03:31 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.
 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.

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December-27-07 12:03:31 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.
 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 .

Helpmelearn
December-27-07 12:03:31 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.
 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 .

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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

New Beetle

WARNING: Cooling system is pressurized, when engine is at operating temperature.

Use caution and use other appropriate protective gear (safety glasses and
gloves) when servicing cooling system. Slowly and carefully release
system pressure, before performing any repairs.

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. 9 or Fig. 10 . Place appropriate
drain pan underneath vehicle.

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 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. 9: Identifying Noise Insulation Mounting Points (New Beetle)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fig. 10: Identifying Noise Insulation Mounting Points (New Beetle Convertible)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

2. Unscrew drain plug (arrow), and drain coolant from radiator. See Fig. 6 .
3. Remove coolant hose from oil cooler, and drain coolant from engine. See Fig. 7 .

CAUTION: DO NOT mix Green with Lilac coolant. Mixing these coolant types will
cause severe engine damage. Use ONLY G 012 A8 F Lilac coolant.
See COOLING SYSTEM SPECIFICATIONS .

NOTE: If filling cooling system, using VAG 6096 Charging Unit, go to step 9 .

4. On vehicles with expansion tank MAX/MIN markings, close drain plug at radiator. Connect oil cooler
hoses. Fill cooling system with recommended coolant mixture. See COOLING SYSTEM
SPECIFICATIONS . Install expansion tank cap. Turn off A/C and heater controls. Start engine, and
raise engine speed to 2000 RPM for approximately 3 minutes. Allow engine to idle, until coolant fan

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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

turns on. Turn ignition off.

5. Check coolant level, and top off as necessary. When engine is at normal operating temperature, coolant
level must be on MAX mark, on expansion tank. See Fig. 11 . When engine is cold, coolant level must be
between MIN and MAX marks, on expansion tank.

Fig. 11: Identifying Expansion Tank Markings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

6. On vehicles without expansion tank markings, 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 (arrow). See Fig. 12 . Install expansion tank
cap.

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 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. 12: Identifying Expansion Tank Hatch Marks

Courtesy of VOLKSWAGEN UNITED STATES, INC.

7. Turn off A/C and heater controls. Start engine, and raise engine speed to 2000 RPM for approximately 3
minutes. Allow engine to idle, until coolant fan turns on. Turn ignition off.
8. Check coolant level, and top off as necessary. When engine is at normal operating temperature, coolant
level must be at upper hatch mark, on expansion tank. See Fig. 12 . When engine is cold, coolant level
should be around middle of hatch mark, on expansion tank.
9. 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
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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

recommended coolant mixture. See COOLING SYSTEM SPECIFICATIONS .

SERVICING

WARNING: Cooling system is pressurized, when engine is at operating temperature.

Wear gloves, and other appropriate protection. Slowly and carefully
release system pressure, before performing any repairs.

Coolant does not usually need replacing. In case of larger repairs when coolant needs to be drained, new coolant
must be used because, old 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. Drain cooling system. See
DRAINING, FILLING & BLEEDING . Flushing system should remove most coolant residue.

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

DRIVE BELT ROUTING

NOTE: Serpentine belt is self-adjusting. See Fig. 13 or Fig. 14 .

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 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. 13: Drive Belt Routing (Without A/C)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 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. 14: Drive Belt Routing (With A/C)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

DRIVE BELT, REMOVING & INSTALLING

Remove engine cover. Rotate serpentine belt tensioner clockwise to relieve belt tension. Remove serpentine
belt. See Fig. 15 . Lock in place using Mandrel (T10060) or a drift.

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 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. 15: Releasing Serpentine Belt Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

COOLING SYSTEM SPECIFICATIONS

COOLANT MIXTURE RECOMMENDATIONS
Application Specification
Freeze Point
Down To -13° F (- 25° C) 40% Coolant
Down To -31° F (- 35° C) 50% Coolant

COOLING SYSTEM SPECIFICATIONS

Application Specification
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 2003 Volkswagen New Beetle GLS
2002-04 ENGINE COOLING Specifications & Drive Belt Routing - 2.0L (AEG, AVH, AZG, BBW, BDC, BEV & BGD
Engine Code)

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.

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December-27-07 12:03:31 PM Page 19 © 2005 Mitchell Repair Information Company, LLC.