Volkswagen New Beetle. Manual - part 1434

 

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Volkswagen New Beetle. Manual - part 1434

 

 

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

Fuel gauge sensor, installed position 

Fig. 2: Identifying Fuel Gauge Sensor 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

Vent valve, checking 

NOTE:

After installing fuel gauge sensor make sure that the supply and return lines are 
securely clipped into the fuel tank.

 

2003 Volkswagen New Beetle GLS 

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

  

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

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Lever in rest position: Closed  

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Lever pushed in direction of arrow: Open 

FUEL FILTER, SERVICING 

1. Return line 

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From Diesel injection pump  

2. Supply line 

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To Diesel injection pump  

3. O-ring 

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Replace  

4. Control valve 

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Installation position: arrow points towards fuel tank  

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When changing filter: remove mounting clip then remove control valve complete with fuel lines  

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Below + 15° C: Passageway to filter open  

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Over + 31° C: Passageway to filter closed  

5. Mounting clip  

6. Return line 

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To fuel tank  

7. Supply line 

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From fuel tank  

NOTE:

Remove fuel tank sealing cover before installing vent valve.

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

8. Fuel filter 

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Fill with Diesel fuel before installing  

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Flow direction is marked by an arrow  

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Do not interchange connections  

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Replace if damaged  

9. Gasket 

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Replace if damaged  

10. Water drain plug 

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To bleed: remove mounting clip then remove control valve complete with attached fuel lines  

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Loosen and allow approx. 100 cc's of fluid to drain  

Fig. 4: Exploded View Of 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 filled fuel tank, observe the following: 

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Before starting repairs, switch on an 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 bare skin! Wear fuel-resistant gloves!  

RULES FOR CLEANLINESS 

WARNING:

Fire hazard. Do NOT smoke or have anything in the area that can ignite 
Diesel fuel.

 

2003 Volkswagen New Beetle GLS 

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

  

When working on the fuel supply/injection system, pay careful attention to the following rules:

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Thoroughly clean all unions and adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

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Carefully cover opened components or seal, if the repair cannot be carried out immediately.  

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Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.).  

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When the system is open: Do not work with compressed air if it can be avoided. Do not move vehicle 
unless absolutely necessary.  

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Make sure that no Diesel fuel runs onto the coolant hoses. Immediately clean any accidental hose 
contamination. Affected hoses must be replaced immediately.  

FUEL TANK, REMOVING AND INSTALLING 

Special tools and equipment 

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VAG 1383 A Engine/transmission jack 

Fig. 5: Identifying VAG 1383 Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1331 Torque wrench 5 to 50 N.m (3.7 to 37 ft lb) 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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