Volkswagen New Beetle. Manual - part 1418

Terminal 1 + socket 63 

Wire resistance: max. 1.5 ohm 

Fig. 5: Identifying Throttle Position And Accelerator Position Sensor Harness Connector 
Terminals (121-Pin ECM) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Continuation for all vehicles 

z

Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+.  

Specified value: INFINITY ohm 

If no malfunction is detected in the wiring and if the voltage supply was OK: 

z

Replace accelerator pedal position sensor. See item 4 .  

z

Erase DTC memory of control module for Diesel - Direct fuel injection system. See DIAGNOSTIC 
MODE 4: RESET/ERASE DIAGNOSTIC DATA .  

z

Generate readiness code. See READINESS CODE, GENERATING . 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Fuel Supply, 1.9L 4-CYL. ALH & BEW - New Beetle

  

1998-2004 ENGINE

Fuel System - New Beetle, 1.8L (APH, AWV & AWP) 

FUEL SUPPLY SYSTEM COMPONENTS, REMOVING AND INSTALLING 

z

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

z

Observe rules for cleanliness. See RULES OF CLEANLINESS .  

Removing and installing fuel tank with its attachments and fuel filter. See FUEL TANK WITH 
ATTACHMENTS AND FUEL FILTER, REMOVING AND INSTALLING . 

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

Electronic Engine Power Control (EPC) system, checking. See ELECTRONIC ENGINE POWER 
CONTROL (EPC) SYSTEM COMPONENTS, CHECKING . 

Servicing parts of the Evaporative Emission (EVAP) system. See EVAPORATIVE EMISSION (EVAP) 
SYSTEM COMPONENTS, SERVICING . 

FUEL TANK WITH ATTACHMENTS AND FUEL FILTER, REMOVING AND INSTALLING 

1. Sealing cap 

z

Secured with strap from MY 2000  

2. Seal 

z

Replace if damaged  

3. Securing screw  

4. Tank flap unit 

z

With rubber cup  

5. Vent pipe 

z

Black  

z

Check securely seated  

NOTE:

z

Hose connections are secured with either spring-type or clamp-type clips. 

z

Always replace clamp-type clips with screw-type clips.  

z

Fuel hoses in engine compartment must only be secured with spring-type 
clips. The use of clamp or screw-type clips is not permissible.  

z

Assembly tool VAS 5024 or hose clip pliers VAG 1921 are recommended 
for installing spring-type clips.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

z

Clipped onto top of fuel tank  

6. Ground connection 

z

Check securely seated  

7. Vent pipe 

z

White  

z

Check securely seated  

z

Checking. See Checking Change-Over Valve  

8. Gravity/overflow valve 

z

To remove valve unclip upward out of support  

z

Check valve for throughflow: 

„

Valve vertical: open  

„

Valve tilted 45°: closed  

9. O-ring 

z

Replace if damaged  

10. Change-over valve 

z

To remove valve, unclip sideways out of support.  

z

Before installing remove sealing cap item 1.  

z

Checking. See Checking Change-Over Valve  

11. Vent pipe 

z

Black  

z

Check securely seated  

z

To EVAP canister. See EVAPORATIVE EMISSION (EVAP) SYSTEM, OVERVIEW , Pos.6  

z

To remove from flange, press release button on connecting piece.  

12. Pressure retaining valve 

z

For fuel tank breathing  

z

Checking. See Checking Pressure Retaining Valve  

13. Vent pipe 

z

Black  

z

Check securely seated  

z

Secure with spring-type clips  

14. Fuel tank 

z

Support with engine and transmission jack VAG 1383 A when removing  

z

Removing and installing. See FUEL TANK, REMOVING AND INSTALLING  

15. Clamping washer  

16. Heat shield 

z

For fuel tank  

17. 25 N.m  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

18. Lock nut, 2 N.m  

19. Fuel tank cover  

20. Securing strap 

z

Note differing length  

z

Installation position: Fixing point (holes) point in direction of travel  

21. Supply pipe 

z

Black  

z

Check securely seated  

z

Press disengaging tabs at connecting piece to pull off fuel filter  

z

To fuel supply hose on fuel rail: 

See Fuel Rail With Injectors, Disassembling And Assembling . 

22. Fuel filter 

z

Installation position: -arrow- points in throughflow direction  

23. Screw-type clip  

24. Vent pipe 

z

White  

z

Check securely seated  

z

Clipped onto side of fuel tank  

z

To EVAP Canister Purge Regulator Valve -N80-  

25. Sealing ring 

z

Replace if damaged  

z

When installing, insert seal "dry" into fuel tank opening  

z

Only coat with fuel when installing fuel delivery unit flange  

26. Fuel delivery unit 

z

Note installation position on fuel tank. See Installation Position Of Fuel Delivery Unit Flange  

z

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

z

Removing and installing fuel gauge sensor. See FUEL GAUGE SENSOR, REMOVING AND 
INSTALLING  

z

Checking fuel pump. See FUEL PUMP, CHECKING  

z

Clean strainer if soiled  

27. Union nut, 75 N.m 

z

Remove and install with spanner 3217  

28. Supply pipe 

z

Black  

z

Check securely seated  

z

Clipped onto side of fuel tank  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)