Volkswagen New Beetle. Manual - part 1438

 

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Volkswagen New Beetle. Manual - part 1438

 

 

z

For filler neck  

10. Vent line 

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Check for secure seating  

11. Clamping washer  

12. Heat shield  

13. Fuel tank cover  

14. 20 N.m plus an additional 90° (1/4 turn) 

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Always replace  

15. Mounting strap 

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Note different lengths  

16. 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  

17. 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 inner edges of seal with fuel when installing fuel gauge sensor  

18. Fuel gauge sensor 

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Observe installed position on fuel tank, See Fig. 2  

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

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Check fuel gauge signal sensor, See FUEL GAUGE SENSOR, CHECKING  

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Check fuel pump. See FUEL PUMP, CHECKING ELECTRICALLY and DELIVERY 
PRESSURE AND DELIVERY RATE OF FUEL PUMP, CHECKING
 .  

19. Union nut 

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Remove and install with key 3217  

20. Supply line 

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Black  

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To fuel filter, See FUEL FILTER, SERVICING  

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Clipped onto fuel tank  

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Check for secure seating  

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Press locking ring inward to release fuel line of fuel gauge sensor  

21. Return hose 

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Blue  

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From fuel cooler, See FUEL COOLER, REMOVING AND INSTALLING  

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Clipped onto fuel tank  

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Check for secure seating  

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Press locking ring inward to release fuel line of fuel gauge sensor 

 

2003 Volkswagen New Beetle GLS 

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

  

22. Distance piece  

23. Gravity/overflow valve 

z

Check valve for through flow: 

Valve vertical: Open, 

Valve tilted 45°: Closed 

24. 10 N.m  

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

Fuel gauge sensor, installed position 

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

Fig. 2: Mark On Fuel Gauge Sensor Flange Must Align With Mark On Fuel Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

Vent valve, checking 

Lever in rest position: Closed 

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

Lever pushed in direction of arrow: Open 

FUEL FILTER, SERVICING 

The flow direction is marked by an arrow on the fuel hose, the preheat valve and the fuel filter. 

1. Return hose 

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To fuel cooler, See FUEL COOLER, REMOVING AND INSTALLING  

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Open lower spring-type clamp  

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Blue or with blue marking  

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Check for secure seating  

2. Supply line 

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From fuel tank  

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White or with white marking  

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Check for secure seating  

NOTE:

After installing fuel gauge sensor, check that the supply -2- and return lines -1- 
are still clipped onto fuel tank.

NOTE:

Before installing breather valve, unscrew filler cap from fuel tank.

NOTE:

The following list refers to items in Fig. 4 .

 

2003 Volkswagen New Beetle GLS 

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

  

3. O-ring 

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Always replace  

4. Securing clip 

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Replace if damaged  

5. Protective plate 

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Note installation position  

6. Control valve 

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Installed position: Arrow points toward fuel tank  

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When changing filter, remove retaining clip and protective plate and take off preheat valve with 
hoses remaining connected. Replace O ring and coat with fuel before installing.  

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Below + 15°C: 

Passageway to filter open 

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Over + 31°C: 

Passageway to filter closed 

7. Return line 

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From tandem pump  

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Open lower spring-type clamp  

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Check for secure seating  

8. Supply line 

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To tandem pump  

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Check for secure seating  

9. Fuel filter 

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Fill with diesel before installing  

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Flow direction is marked by arrows  

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Do not interchange connections  

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Replace if damaged  

10. Tensioning bolt, 2 N.m  

11. Bracket 

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Slide onto upper stop of fuel filter  

12. Water drain plug 

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To bleed: remove retaining clip and protective plate and remove preheat valve with hoses 
remaining connected  

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Loosen and allow approx. 100 cc of fluid to drain  

13. Seal 

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Replace if damaged.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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