Volkswagen New Beetle. Manual - part 1421

 

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Volkswagen New Beetle. Manual - part 1421

 

 

See AXLE BEAM 

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Drain fuel tank and clean fuel filler neck and surrounding area.  

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Unscrew securing bolts and remove tank flap unit with rubber cup.  

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Remove securing bolt on filler neck.  

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Fold rear seat bench forward.  

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Remove fuel gauge sensor cover plate and disconnect connector.  

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Remove cover from under fuel tank. 

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Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting 
point. 

Fig. 13: Disconnecting Return Hose, Supply Hose And Breather Hose At Connecting Point 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove tensioning strap. When doing this support fuel tank with engine/transmission jack VAG 1383 A. 

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Lower fuel tank.  

Installing 

Installation is carried out in the reverse order; when doing this note the following: 

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Breather hoses are to be installed kink-free.  

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Fuel hoses are to be installed kink-free. 

WARNING:

Fuel supply hoses are under pressure! Before removing from hose 
connection wrap a cloth around the connection. Then release 
pressure by carefully pulling hose off connection.

NOTE:

Press buttons on hose couplings to do this.

 

2003 Volkswagen New Beetle GLS 

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

  

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Make sure fuel hoses are seated securely.  

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Secure fuel hoses with spring-type clamps.  

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

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Check DTC memory. 

See Diagnostic Trouble Code (DTC) Memory, Checking And Erasing . 

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Read readiness code. 

See Readiness Code, Displaying . 

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Match engine electronics control module to throttle valve control module. 

See Engine Control Module (ECM) To Throttle Valve Control Module, Adapting . 

REPLACEMENT FUEL TANKS, INSTALLING GROUND STRAP 

Condition 

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

Installing 

Install ground strap Part No. 1 J0 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 the fuel gauge sensor, check that the supply, return and 
breather pipes 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.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: 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. 15: Inserting End -A- Of Ground Strap Through Slot In Tab Up To Bend -B- At Other End Of 
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 

Vehicles with an airbag are equipped with a crash fuel shut-off system. It reduces the danger of a fire in a crash 

NOTE:

Illustration shows ground strap already installed.

 

2003 Volkswagen New Beetle GLS 

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

  

as the fuel pump is switched off via the fuel pump relay.

Simultaneously this system provides an improved start for the engine. When the door is opened the fuel pump is 
activated for 2 seconds to build-up the pressure in fuel system. 

When opening the fuel system: 

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

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Check activation of fuel pump relay using wiring diagram and VAG1466 A: 

See appropriate WIRING DIAGRAM article 

FUEL PUMP, CHECKING 

Special tools and equipment 

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3217 Ring nut wrench  

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VAG 1348/3A Remote control with VAG 1348/3-2 adapter cable  

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VAG 1466 Test system  

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VAG 1527 BLED test light  

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VAG 1594 A Adapter set  

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VAG 1715 Multimeter 

Fig. 16: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1318 Pressure tester  

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VAG 1318/1 Adapter  

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VAG 1318/11 Adapter  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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