Volkswagen New Beetle. Manual - part 1435

Fig. 6: Identifying VAG 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Note safety precautions before starting work. See SAFETY PRECAUTIONS WHEN WORKING ON 
THE FUEL SUPPLY SYSTEM . 

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Open fuel filler.  

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With ignition switched off disconnect battery Ground strap.  

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Remove rear axle: 

See FRONT AXLE SHAFT . 

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Remove right rear wheel housing liner: 

See REAR WHEEL HOUSINGS LINER, ASSEMBLY OVERVIEW . 

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Remove cover from fuel reservoir (arrows). 

CAUTION: Obtain radio anti-theft code before disconnecting battery Ground 

strap.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - 1.9L 4-Cyl. - ALH, New Beetle

  

Fig. 7: Removing Cover From Fuel Reservoir 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drain fuel tank, clean fuel filler neck and surrounding area.  

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Disconnect vent lines at filler neck  

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Press separated vent hose through opening in long member in fuel tank direction.  

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Remove mounting bolts on filler neck.  

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Fold rear bench seat forward.  

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Remove fuel gauge sensor cover plate.  

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Disconnect fuel supply and return lines front, right at fuel reservoir 

Fig. 8: Disconnecting Fuel Supply And Return Lines Front 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove tensioning strap. While removing strap, support fuel tank with VAG 1383 A engine/transmission 
jack.  

NOTE:

Press buttons on hose couplings (arrows) to do this.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - 1.9L 4-Cyl. - ALH, New Beetle

  

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Lower fuel tank.  

Installing 

Installation is carried out in the reverse order of the removal procedure. Note the following during installation: 

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Guide vent lines through opening in long member (install wiring guide)  

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Secure vent lines at filler neck with clamps  

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Route breather hoses kink free.  

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Do not interchange supply and return hoses (return: blue or blue markings, supply: black).  

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Clip supply and return lines onto fuel tank.  

ACCELERATOR MECHANISM, SERVICING 

1. 10 N.m (7 ft lb)  

2. Throttle Position (TP) sensor -G79- 

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Checking. See THROTTLE POSITION SENSOR, CHECKING .  

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Adjusting: See THROTTLE POSITION SENSOR, ADJUSTING .  

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Remove if instrument panel and/or pedal cluster cover require removal  

3. Cable cam  

4. Spring washer 5-10 N.m (7 ft lb)  

5. Threaded piece  

6. Mounting bracket 

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Self-locking hex nut, 20 Nm (15 ft. lb)  

Fig. 9: Disassembled View Of Accelerator Mechanism 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

The following list refers to items in Fig. 9 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - 1.9L 4-Cyl. - ALH, New Beetle

  

THROTTLE POSITION SENSOR, CHECKING

Special tools and equipment 

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Fluke 83 multimeter  

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VW 1594 Adaptor kit  

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VAG 1598/22 Test Box  

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VAG 1551/1552 Scan Tool with VAG 1551/3 adaptor cable  

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Wiring diagram 

Fig. 10: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test sequence 

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Connect VAG 1551/1552 Scan Tool: 

See VAG1551/1552 Scan Tool, Connecting . 

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Make sure that ignition is switched ON.  

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Press 0 and 1 buttons to select Address word 01: "Engine electronics".  

Display will appear as shown in Fig. 11 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - 1.9L 4-Cyl. - ALH, New Beetle