Volkswagen New Beetle. Manual - part 1439

14. 10 N.m

Fig. 4: Identifying Fuel Filter Assembly
Courtesy of VOLKSWAGEN OF AMERICA, INC.

SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM

When removing and installing the fuel gauge sensor from a full or partly full fuel tank, observe the following:

Before starting repairs, switch on exhaust extraction system and place an extraction hose close to the
sensor opening in the fuel tank to extract escaping diesel fuel fumes. If no exhaust extraction system is
available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m

/h can

be used.

Avoid fuel contact with skin! Wear fuel-resistant gloves!

CAUTION: When performing repair work, especially due to the confined conditions in

the engine compartment, pay attention to the following:

Route all types of hoses/lines (e.g. for fuel, hydraulics, EVAP system,
coolant, refrigerant, brake fluid and vacuum) as well as electrical
wiring so that the original positions are restored.

Ensure sufficient clearance to all moving or hot components.

WARNING:

The fuel and the fuel lines in the fuel system can become very hot
(danger of scalding)!

The fuel system is under pressure! Before opening the system,
place cloths around the connections. Then carefully loosen the
connection to release pressure

Wear eye and hand protection when performing any type of repair
work on the fuel system!

2003 Volkswagen New Beetle GLS

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

RULES FOR CLEANLINESS

When working on the fuel supply/injection system, pay careful attention to the following rules:

Thoroughly clean all unions and adjacent areas before disconnecting.

Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!

Carefully cover opened components or seal if repairs cannot be carried out immediately.

Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (e.g. in tool boxes etc.).

When the system is open: Do not work with compressed air if this can be avoided. Do not move vehicle
unless absolutely necessary.

Make sure that no diesel fuel runs onto the coolant hoses. Immediately clean any accidental hose
contamination. Affected hoses must be replaced.

FUEL COOLER, REMOVING AND INSTALLING

Observe safety precautions, See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY
SYSTEM .

Observe rules for cleanliness, See RULES FOR CLEANLINESS .

Special tools and equipment

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

Fig. 5: Identifying Special Tools And Equipment (V.A.G 1331)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Removing

NOTE:

The fuel cooler is located in the fuel return line to the tank. It is located on the

2003 Volkswagen New Beetle GLS

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

Remove cover -A-.

Separate fuel lines at fuel cooler.

Fig. 6: Locating Fuel Cooler
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Remove securing nuts (arrows).

Installing

Installation is performed in the reverse sequence of removal. Note the following:

Tighten fuel cooler securing nuts to 20 N.m.

Fig. 7: Removing Fuel Cooler Securing Nuts
Courtesy of VOLKSWAGEN OF AMERICA, INC.

vehicle underbody.

2003 Volkswagen New Beetle GLS

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

FUEL DELIVERY UNIT, REMOVING AND INSTALLING

Observe safety precautions, See SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY
SYSTEM .

Observe rules for cleanliness, See RULES FOR CLEANLINESS .

Special tools and equipment

3217 Ring nut wrench

Fig. 8: Identifying Special Tools And Equipment (3217 Ring Nut Wrench)
Courtesy of VOLKSWAGEN OF AMERICA, INC.

Removing

Check whether a coded radio is installed. If so, obtain anti-theft coding.

With ignition switched off disconnect battery Ground (GND) strap.

Fold rear seat bench forward.

Remove cover from fuel delivery unit.

4-pin connector as well as supply and return lines must be disconnected from the fuel delivery unit.

WARNING:

The fuel and the fuel lines in the fuel system can become very hot
(danger of scalding)!

The fuel system is also under pressure! Before opening the system,
place cloths around the connections. Then carefully loosen the
connection to release pressure

Wear eye and hand protection when performing any type of repair
work on the fuel system!

2003 Volkswagen New Beetle GLS

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

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