Volkswagen New Beetle. Manual - part 1144

Fig. 5: Evaporative Emissions (EVAP) Canister Purge Regulator Valve Hoses - Engine Codes AEG, 
AVH, AZG 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine code BDC 

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Pull fuel supply line -1- as well as fuel return line -2- off fuel rail and collect fuel that leaks out with a 
clean cloth.  

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Pull hose off Evaporative Emissions (EVAP) canister purge regulator valve -N80-.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 6: Locating Fuel Supply/Return Lines & EVAP Canister Purge Regulator Valve - Engine Code BDC
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Engine codes BEV, BGD 

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Pull fuel supply line -1- off union by pressing locking ring -2- into union -3- and collect fuel that leaks 
out with a clean cloth. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

Fig. 7: Locating Fuel Supply Line Locking Ring - Engine Codes BEV, BGD 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all models 

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Seal lines to avoid contamination of fuel system.  

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Pull vacuum and breather hoses off engine.  

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Remove air cleaner with intake hose and Mass Air Flow (MAF) -G70-.  

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Remove intake manifold upper part. See INTAKE MANIFOLD UPPER PART, REMOVING AND 
INSTALLING . 

Vehicles with manual transmission 

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Disconnect shift mechanism from transmission. 

See SELECTOR MECHANISM 

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Remove hydraulic clutch slave cylinder: 

See CLUTCH SLAVE CYLINDER . 

Vehicles with automatic transmission 

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Remove selector lever cable from transmission: 

For transmission 01M, see SELECTOR LEVER CABLE 

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Remove selector lever cable from transmission. 

NOTE:

Seal the intake ports in the intake manifold lower section with clean cloths.

NOTE:

The clutch pedal must not be operated.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD

  

For transmission 09G, see SELECTOR MECHANISM

Continuation for all models 

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Remove insulation tray. 

See NOISE INSULATION, ASSEMBLY OVERVIEW 

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Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .  

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Remove ribbed belt. See RIBBED BELT, REMOVING AND INSTALLING .  

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Remove supplementary coolant fan on right side of vehicle, if part of original equipment.  

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Remove power steering pressure line securing clamps on engine and transmission.  

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Remove power steering pump from bracket and tie up to front panel; hoses remain connected. 

See POWER STEERING PUMP, RESERVOIR, HYDRAULIC LINES . 

Vehicles with air conditioning 

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Remove air conditioning compressor: 

See CONDENSER, REMOVING AND INSTALLING . 

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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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Disconnect inter-connecting, coolant, vacuum and intake lines on engine.  

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Separate connections on following components: 

Ignition coils -N- and -N128- with 

Final output stage -N122- or Ignition coils with 

Final output stage -N70-, -N127-, -N291-; -N292- 

Camshaft Position (CMP) sensor -G40- 

Injectors -N30-...-N33-, release cable guide 

Engine Coolant Temperature (ECT) sensor -G62- 

Engine speed (RPM) sensor -G28- 

Knock Sensor (KS) 1 -G61- 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Engine Mechanical - New Beetle, 2.0L 4-Cyl. - AEG, AVH, AZG, BDC, BEV, BGD