Volkswagen New Beetle. Manual - part 1485

1. Cover  

2. Seal 

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Replace if damaged  

3. 1 N.m  

4. Tank flap unit 

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With rubber cup  

5. 10 N.m  

6. Breather pipe  

7. Change-over valve 

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To remove valve unclip sideways out of socket  

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Remove cap item -1- before installing  

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Check. See Checking Change-Over Valve  

8. O-ring 

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Replace if damaged  

9. To EVAP canister 

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See EVAP SYSTEM COMPONENTS, SERVICING  

10. Cable guide 

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In longitudinal member  

11. Breather pipe 

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Check if seated securely  

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Secure with spring-type clips  

12. Fuel tank 

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When removing, support with engine/transmission jack V.A.G 1383 A 

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Removing and installing. See FUEL TANK, REMOVING AND INSTALLING  

13. Heat shield 

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For fuel tank  

14. Clamping washer  

15. Fuel tank cover  

16. 20 N.m + 1/4 turn (90°) further 

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Replace  

17. Securing strap 

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Note differing lengths  

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Installed position: Fixing point (holes) point in direction of travel (forward)  

18. Fuel filter 

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Installed position: Arrow points in direction of flow 

Engine codes BEV, BGD: 

 

2003 Volkswagen New Beetle GLS 

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

  

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Removing and installing fuel pressure regulator. See Removing And Installing Fuel Pressure 
Regulator  

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If fuel filter has been replaced, fuel system must be bled. See FUEL SYSTEM, BLEEDING .  

19. Screw-type clip 

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Observe installed position. See Installed Position Of Screw-Type Clamp For Fuel Filter  

20. Supply line 

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Black  

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Check if seated securely  

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To pull off of fuel filter press locking ring inward on connecting piece  

21. Breather pipe 

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White  

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Clipped onto top of fuel tank  

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Check if seated securely  

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To EVAP canister purge regulator valve -N80-.  

22. Seal 

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Replace if damaged  

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When installing, insert seal dry into fuel tank opening  

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Moisten with fuel only when installing fuel delivery unit flange.  

23. Fuel delivery unit 

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Observe installed position of flange on fuel tank. See Installed Position Of Flange Of Fuel 
Delivery Unit .  

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Removing and installing. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

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Removing and installing fuel gauge sender. See FUEL GAUGE SENDER, REMOVING AND 
INSTALLING .  

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Checking fuel pump. See FUEL PUMP, CHECKING .  

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Clean strainer if soiled  

24. Union nut, 75 N.m 

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Remove and install with key 3217  

25. Supply line 

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Black  

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Check if seated securely  

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Clipped onto side of fuel tank  

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When pulling off flange and fuel filter press locking ring on connecting piece  

26. Return line 

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Blue or with blue marking  

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Clipped onto side of fuel tank  

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Check if seated securely  

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To remove from flange press release button on connecting piece 

 

2003 Volkswagen New Beetle GLS 

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

  

Engine codes BEV, BGD: 

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From fuel filter 

All other engines: 

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From fuel return line on fuel rail  

27. Gravity valve 

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To remove valve unclip upward out of support  

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Check valve for through flow, Valve vertical: Open; Valve tilted 45° : Closed  

28. Pressure retention valve 

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For fuel tank breather  

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Checking. See Checking Pressure Retention Valve  

29. Ground connection 

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Check if seated securely  

Fig. 3: Exploded View Of Fuel Tank/Fuel Filter Components 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installed Position Of Flange Of Fuel Delivery Unit 

Marking on sender must align with the marking on fuel tank (arrows).

 

2003 Volkswagen New Beetle GLS 

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

  

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)