Volkswagen New Beetle. Manual - part 1450

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Lower fuel tank. Guide breather hoses/lines through longitudinal member while lowering tank.  

Installing 

Install in reverse sequence. Note the following points:  

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Route breather and fuel hoses kink free.  

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Ensure tight fit of fuel hoses.  

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Guide breather hoses/lines through opening in longitudinal member (install line guide).  

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Secure breather hoses/lines to filler neck with spring-type clamp.  

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

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Adapt (match) engine control module to throttle valve control module. See COMPONENTS AND 
FUNCTIONS, ADAPTING .  

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If fault memory has been erased or engine control module was disconnected from permanent positive, 
adapt respective components to engine control module (see COMPONENTS AND FUNCTIONS, 
ADAPTING ) and generate readiness code again.  

GROUND STRAP FOR REPLACEMENT FUEL TANKS, INSTALLING 

Condition 

All replacement fuel tanks do not come with Ground strap (wire) installed. 

Installing 

Install Ground strap Part No. 1J0 201 184 into replacement fuel tank as follows: 

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Remove fuel filler cap and observe cautions printed on cap.  

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Bend up tab on inside of fuel filler pipe as shown (arrow). 

NOTE:

After installing fuel gauge sender, check that the supply, return and breather 
lines are still clipped onto the fuel tank.

NOTE:

The Ground strap must be installed into all replacement fuel tanks.

CAUTION: Part numbers are for reference only. Always check with your Parts Dept. 

for the latest parts information.

NOTE:

Fig. 21 shows Ground strap already installed.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 21: Bending Up Tab On Inside Of Fuel Filler Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Insert end -A- of Ground strap through slot in tab up to bend -B- at other end of strap. 

Fig. 22: Identifying Ground Strap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Bend down tab on inside of fuel filler pipe. This will secure strap to end of tab.  

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Reinstall fuel filler cap.  

CRASH FUEL SHUT-OFF 

Function 

Models with an airbag are equipped with a crash fuel shut-off system. This system reduces the danger of a fire 
in a crash in that the fuel pump is switched off via the fuel pump relay. At the same time this system improves 
starting of the engine. When the door is opened the fuel pump is activated for 2 seconds to build up pressure in 
the fuel system. 

 

2003 Volkswagen New Beetle GLS 

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

  

When opening the fuel system:  

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

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Check activation of fuel pump relay using wiring diagram and V.A.G 1466 A: See appropriate SYSTEM 
WIRING DIAGRAM article.  

FUEL PUMP, CHECKING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

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3217 Union nut spanner  

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V.A.G 1318 Pressure gauge  

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V.A.G 1318/11 Adapter  

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V.A.G 1318/16 Hose adapter  

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V.A.G 1318/17 Adapter  

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V.A.G 1318/23 Adapter 

Fig. 23: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1332 Torque wrench (40...200 N.m)  

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V.A.G 1348/3A Remote control with adapter cable V.A.G 1348/3-2  

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V.A.G 1527 B Diode test lamp  

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V.A.G 1594 A Adapter set  

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V.A.G 1715 Multimeter  

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Measuring container  

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Wiring diagram  

Requirements 

 

2003 Volkswagen New Beetle GLS 

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

  

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Fuse 28 must be OK. 

Fig. 24: Locating Fuse Box (Behind Access Panel At Far Left End Of Dash) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Battery voltage must be at least 11.5 V.  

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All electrical consumers, e.g. lights and rear window defogger must be switched off.  

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If the vehicle is equipped with air conditioning, this must be switched off.  

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On models with an automatic transmission selector lever in position "P" or "N" 

Checking function and voltage supply 

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Remove cover from fuel delivery unit.  

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Briefly operate starter; fuel pump must be audibly starting.  

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Switch off ignition.  

If the fuel pump does not run: 

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Remove cover in front of fuse holder.  

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Pull fuse No. 28 out of fuse holder.  

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Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 28a to fuel pump 
and battery positive (+). 

NOTE:

Observe description of function of crash fuel shut-off. See CRASH FUEL 
SHUT-OFF .

 

2003 Volkswagen New Beetle GLS 

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