Volkswagen New Beetle. Manual - part 1477

22. Distance piece  

23. Gravity/overflow valve 

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Check valve for through flow: 

Valve vertical: Open, 

Valve tilted 45°: Closed 

24. 10 N.m  

Fig. 1: Exploded View Of Fuel Tank Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Fuel gauge sensor, installed position 

Mark on flange must align with mark on fuel tank (arrows). 

Fig. 2: Mark On Fuel Gauge Sensor Flange Must Align With Mark On Fuel Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Vent valve, checking 

Lever in rest position: Closed 

Fig. 3: Checking Vent Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Lever pushed in direction of arrow: Open 

FUEL FILTER, SERVICING 

The flow direction is marked by an arrow on the fuel hose, the preheat valve and the fuel filter. 

1. Return hose 

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To fuel cooler, See FUEL COOLER, REMOVING AND INSTALLING  

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Open lower spring-type clamp  

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Blue or with blue marking  

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Check for secure seating  

2. Supply line 

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From fuel tank  

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White or with white marking  

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Check for secure seating  

NOTE:

After installing fuel gauge sensor, check that the supply -2- and return lines -1- 
are still clipped onto fuel tank.

NOTE:

Before installing breather valve, unscrew filler cap from fuel tank.

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. O-ring 

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Always replace  

4. Securing clip 

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Replace if damaged  

5. Protective plate 

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Note installation position  

6. Control valve 

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Installed position: Arrow points toward fuel tank  

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When changing filter, remove retaining clip and protective plate and take off preheat valve with 
hoses remaining connected. Replace O ring and coat with fuel before installing.  

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Below + 15°C: 

Passageway to filter open 

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Over + 31°C: 

Passageway to filter closed 

7. Return line 

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From tandem pump  

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Open lower spring-type clamp  

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Check for secure seating  

8. Supply line 

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To tandem pump  

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Check for secure seating  

9. Fuel filter 

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Fill with diesel before installing  

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Flow direction is marked by arrows  

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Do not interchange connections  

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Replace if damaged  

10. Tensioning bolt, 2 N.m  

11. Bracket 

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Slide onto upper stop of fuel filter  

12. Water drain plug 

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To bleed: remove retaining clip and protective plate and remove preheat valve with hoses 
remaining connected  

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Loosen and allow approx. 100 cc of fluid to drain  

13. Seal 

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Replace if damaged.  

 

2003 Volkswagen New Beetle GLS 

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

  

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: 

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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

3

 /h can 

be used.  

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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: 

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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.  

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Ensure sufficient clearance to all moving or hot components.  

WARNING:

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

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

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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