Volkswagen New Beetle. Manual - part 1447

Fig. 4: Aligning Fuel Delivery Unit Flange With The Marking On Fuel Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Blue or blue marked return line -1- to connection with identification -R-. 

Black supply line -2- to connection with identification -V-. 

Checking Change-Over Valve 

Lever in rest position: Closed 

Lever pushed in direction of arrow: Open 

Fig. 5: Checking Change-Over Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

After installing fuel delivery unit flange, check that the supply, return and 
breather pipes are still clipped onto the fuel tank.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Checking Pressure Retention Valve 

The pressure retention valve is opened in both through-flow directions from the gravity valve/pressure retention 
valve (arrow -1-). 

Fig. 6: Checking Pressure Retention Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is opened only in one through-flow direction from the EVAP system/solenoid valve junction piece (arrow -2-
). 

Checking direction of valve flow. See CHECKING DIRECTION OF VALVE FLOW . 

Checking direction of valve flow 

A. Union 1 1: 

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Flow in both directions  

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Union -2- is closed  

B. Union 1 - 2: 

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Flow in both directions  

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Union - 3 is closed  

C. Union 1 2: 

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Flow in only one direction  

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Union -3- is closed  

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Valve must close when a vacuum is applied to union -1-

NOTE:

Before installing vent valve remove cap from fuel tank.

NOTE:

The following list refers to items in Fig. 6 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Installed Position Of Screw-Type Clamp For Fuel Filter

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Install screw-type clamp (arrow) as shown in illustration. 

Ensure sufficient clearance between clamp fastener and fuel tank: 

Dimension "a" must be at least 5 mm 

Fig. 7: Identifying Installed Position Of Screw-Type Clamp For Fuel Filter 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing And Installing Fuel Pressure Regulator 

1. Fuel filter 

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Arrows show flow direction  

2. Rubber hose  

3. Retaining clip 

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Check if seated securely  

4. Ground strap 

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Mounted on fuel filter retainer  

5. Supply pipe 

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From fuel pump  

6. Return pipe 

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To fuel pump  

7. Fuel pressure regulator 

NOTE:

The fuel filter is illustrated viewed from the front.

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

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Checking. See FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, 
CHECKING .  

8. Seal 

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Replace  

9. O-ring 

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Replace  

10. Supply pipe 

z

To union in fuel tank  

Fig. 8: Exploded View Of Fuel Filter & Fuel Pressure Regulator Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM 

When removing and installing the fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full 
fuel tank the following must be observed: 

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Before beginning work, switch on the exhaust extraction system and place an extraction hose close to the 

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

the engine compartment, pay attention to the following: 

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Route all types of 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.  

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Ensure sufficient clearance to all moving or hot components.  

WARNING:

Fuel supply lines are under pressure! Before removing a hose connection 
wrap a cloth around the connection. Then release pressure by carefully 
pulling the hose off the connection.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)