Volkswagen New Beetle. Manual - part 1754

Fig. 14: Locating Fuel Supply Line (2.0L - Engine Codes BEV & BGD) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

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Fig. 15: Connecting Fuel Pressure Gauge To Engine (2.0L - BEV & BGD) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

3. Reinstall fuel pump (No. 28) fuse in dash fuse box.  

4. Start engine and idle. Fuel pressure should be within specification. See FUEL PRESSURE 

SPECIFICATIONS (1.8L TURBO & 2.0L) table. Continue to idle engine.  

5. If fuel pressure is not as specified, check fuel pump check valve and fuel pressure regulator. See FUEL 

PUMP CHECK VALVE . See FUEL PRESSURE REGULATOR TEST (2.0L - ENGINE CODES 
BEV & BGD) . If fuel pressures are okay, go to next step.  

6.  

Perform fuel system residual pressure test. Continue to run engine at idle. Turn engine off. Check for fuel 
leaks. Check residual fuel pressure after 10 minutes. See FUEL PRESSURE SPECIFICATIONS (1.8L 

NOTE:

Fuel system residual pressure (holding pressure) test checks integrity of 
fuel lines, fuel fittings, fuel pressure regulator, fuel injectors and fuel pump 
check valve. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

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© 2004 Mitchell Repair Information Company, LLC. 

TURBO & 2.0L) table. If residual pressure drops below specification, start engine and run at idle speed.  

7. Switch ignition off after pressure has built up. At same time, close pressure gauge cut-off handle (handle 

at 90 degrees to fuel flow direction). See Fig. 8 . Gauge will now read fuel isolated in fuel rail.  

8. If residual fuel pressure does NOT drop, check fuel pump check valve and fuel pressure regulator. See 

FUEL PUMP CHECK VALVE . See FUEL PRESSURE REGULATOR TEST (2.0L - ENGINE 
CODES BEV & BGD) . If residual pressure drops again, go to next step.  

9. If fuel pressure drops again, check fuel lines, connections and "O" rings for leaks. Check pressure gauge 

for leaks. Check for leaking fuel injectors. Perform fuel injector leak test. See appropriate SYSTEM & 
COMPONENT TESTING article.  

Fuel Pressure Regulator Test (2.0L - Engine Codes BEV & BGD) 

1. BEFORE check fuel pressure regulator, ensure fuel pump check valve is operating correctly. See FUEL 

PUMP CHECK VALVE . Ensure fuel supply line is not leaking.  

2. Turn off ignition. Remove fuse No. 28 from fuse block at far left end of dash. See Fig. 3 .  

3. Connect VAG1348/3A remote control to fuse 28 socket. Connect one end to B+ and other to appropriate 

fuse socket cavity. See Fig. 17 .  

4. Connect VAG1318 pressure gauge with adapters, or equivalent, to fuel supply line on fuel rail. To 

remove fuel supply hose, slide safety ring (2) in the union (1). See Fig. 14 . Do not connect pressure 
gauge to fuel rail. Place fuel pressure gauge line in a fuel measuring container. See Fig. 16 .  

5. Close shut-off valve on fuel pressure gauge. Lever is at right angles to direction of flow. See B in Fig. 

16 .  

6. Operate VAG1348/3A remote control until pressure gauge reads 58 psi (4 bar). If pressure builds up too 

high, bleed off until correct pressure is obtained.  

7. Watch pressure on fuel gauge. Over a period of 30 minutes, pressure may not drop below 46.2 psi (3.2 

bar). If the pressure drops, check line connections for proper sealing. If fuel lines are okay, replace fuel 
pressure regulator.  

FUEL PUMP VOLUME CHECK (EXCEPT 2.0L ENGINE CODES BEV & BGD) 

NOTE:

The 2.0L engine Codes BEV and BGD is equipped with non-return type fuel 
system. Fuel pressure regulator is part of fuel pump assembly. 

CAUTION: Models with airbag are equipped with crash fuel shut-off system. Fuel 

shut-off system reduces danger of fire in a crash when fuel pump is 
switched off via 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 the pressure in fuel system. 

WARNING:

Fuel system is under pressure. Before opening fuel system place cloth 
around connection. Then release pressure by carefully loosening 
connection. Always wear eye protection and wear fuel-resistant gloves 
when disconnecting fuel system connections. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:30 AM

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© 2004 Mitchell Repair Information Company, LLC. 

1. Remove fuel filler cap. Connect VAG1318 pressure gauge with adapters, or equivalent, to fuel supply 

line on fuel rail. Push buttons on hose couplings to release fuel lines. Do not connect pressure gauge to 
fuel rail. Place fuel pressure gauge line in a fuel measuring container. See Fig. 16 . 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:30 AM

Page 21 

© 2004 Mitchell Repair Information Company, LLC.