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Re: Replace radiator on 2003 new beetle - 2.0 GLS
First you empty water, then remove fan, and radiator. You need to follow the step by step procedure from a manual, buy the haynes manual for new beetle here is an example on ebay. Replacing radiator is not a difficult operation, but if you do not do it properly you can damage your car, check that fan is working, water pump is running ok and that there is no leaking after doing the job.
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Check this procedure to how to replace a water pump (DIY Complexity: Moderate / Time: 3.5 hours):
Parts: 1. Water Pump
Tools: 1. Screwdriver 2. Scraper 3. 3/8 in. Drive Ratchet 4. Cooling System Pressure Tester 5. Needle Nose Pliers 6. Socket Set 7. Radiator Hook Tool
Supplies: 1. Coolant 2. Silicone Sealant
Steps: Step 1 With the engine off and cold, open the hood and locate the vehicle’s water pump. o Tip: Safety Tip:Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or safety shoes. o Tip: Before removing the radiator cap, squeeze the upper radiator hose to verify that the cooling system is not pressurized.
Step 2 Remove the radiator cap.
Step 3 Install cooling system pressure tester. Apply the pressure indicated on the radiator cap or in the owner’s manual.
Step 4 Inspect cooling system components for leaks.
Step 5 Place a drain pan under the radiator. Open drain valve or remove the lower radiator hose to drain cooling system. o Tip: Depending on the vehicle, lifting the vehicle may be required to gain access to the lower radiator hose.
Step 6 Remove the drive belts or serpentine belt.
Step 7 Remove any hoses connected to water pump.
Step 8 Unbolt water pump from engine. Remove the water pump.
Step 9 Using a gasket scraper, clean the mating surface on the engine block.
Step 10 Install new water pump and new gasket. Tighten bolts to manufacturer’s specifications. o Tip: You may want to use a light bead of silicone designed for water pumps.
Step 11 Re-install any hoses and belts that were removed.
Step 12 Re-install drain plug or lower radiator hose. o Tip: Squeeze the radiator hose. If it feels soft you may want to replace the hose at this time. Always use new hose clamps.
Step 13 Refill radiator with a 50/50 mix of coolant and distilled water, then pressure test the cooling system and check for leaks.
Step 14 Fill overflow reservoir with same mixture.
Step 15 Leave the radiator cap off, start engine and let it idle. You should see the system“burping” bubbles of air. Refill the radiator to the top. o Tip: Most air is expelled after a couple minutes of idling. Be cautious of potentially hot fluid overflowing.
Step 16 Install radiator cap.
Step 17 Road test vehicle, keep an eye on the engine temp gauge if vehicle runs hot, there still might be an air pocket in the cooling system. The cooling system should be topped off after vehicle has fully cooled down.
If you follow your upper radiator hose back to where it attaches to the engine, that is where the thermostat is located. it is called the thermostat housing and it is held onto the engine with 2 or 3 bolts. If you purchase the thermostat from an auto parts store, they often can give you some specific guidance too. Of course, you need to start this project with the engine cold, and first drain the coolant out of the system. Make sure you have a new gasket or sealant to install teh new thermostat too.
CODE P2181 COOLING SYSTEM PERFORMANCE MALFUNCTION CONDITIONS - ECT SENSOR HAS FAILED. 2.0L ENGINE ECT LOCATION IS ON THE UPPER RADIATOR HOSE CONNECTION AT THE REAR OF THE CYLINDER HEAD. 2.5L ENGINE ECT IS ON THE UPPER RADIATOR HOSE CONNECTION ON THE CYLINDER HEAD ALSO.CHECK COOLING FAN FUSE AND RELAYS
Im actually going through the process of fixing this problem with my car. the P2181 is a performance cooling error, usually brought up by thermostat, radiator issues, or ECT sensor. You should narrow it down and check both radiator and thermostat to prevent later issues. If all is well go to your local autozone, pep boys, checkers..etc. and have them erase the DTC error. If you are looking for a more long term solution you can purchase many different software such as VAG-COM or any other software used to run test on vehicals. Be sure you know what you are doing though because messing with your cars computer can have long term effects that can be pricey.