Volkswagen New Beetle. Manual - part 1440

 

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Volkswagen New Beetle. Manual - part 1440

 

 

z

Remove union nut with wrench 3217.  

z

Pull fuel gauge sensor and seal out of opening in fuel tank. 

Fig. 9: Removing Fuel Gauge Sensor Union Nut With Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Installation of the fuel delivery unit is performed in reverse order. 

NOTE:

Press locking ring inward to release fuel lines.

NOTE:

If the delivery unit is to be replaced drain old delivery unit before disposal.

NOTE:

z

Do not bend fuel sensor when installing.  

z

Insert fuel delivery unit seal dry into fuel tank opening.  

z

Moisten inner edges of seal with fuel only when installing fuel delivery 
unit.  

z

Note installation position of fuel gauge sensor: The marking on the fuel 
delivery unit must align with marking on fuel tank (arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Check Diagnostic Trouble Code (DTC) memory. See ENGINE CONTROL MODULE (DTC) 
MEMORY, READING AND ERASING
 .  

FUEL GAUGE SENSOR, REMOVING AND INSTALLING 

Removing 

z

Remove fuel gauge sensor. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

z

Unlock line connector -1 - and -2- and pull off.  

z

Lift up retaining tabs -3- and -4- using a screwdriver and pull fuel sensor off downward (arrows). 

Fig. 11: Removing And Installing Fuel Delivery Unit Connectors

Fig. 10: Aligning Fuel Delivery Unit Marking With Marking On Fuel Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

Courtesy of VOLKSWAGEN OF AMERICA, INC.

Installing 

z

Insert fuel gauge sender in guides on fuel gauge sensor and push up until it engages.  

z

Connect connectors and check for secure fit.  

z

Install fuel gauge sensor, See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

FUEL GAUGE SENSOR, CHECKING 

Special tools and equipment 

z

V.A.G 1526 Multimeter 

Fig. 12: Identifying Special Tools And Equipment (V.A.G 1526 Multimeter) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1594 A Adapter set 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Identifying Special Tools And Equipment (V.A.G 1594 A Adapter Set) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Remove cover from fuel gauge sensor.  

z

Disconnect 4-pin connector from flange on fuel gauge sensor.  

z

Measure resistance at contacts -2- and -3- on sealing flange. 

Fig. 14: Measuring Resistance At Contacts -2- And -3- On Fuel Gauge Sensor Sealing Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

FUEL GAUGE SENSOR RESISTANCE 

With a fuel gauge between "full" and "empty" there must be indicated a resistance value between both 
specifications. 

If 0 ohm or infinite ohms is measured, there is a wiring open or short circuit. 

FUEL TANK, REMOVING AND INSTALLING 

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

Observe rules for cleanliness. See RULES FOR CLEANLINESS .

Sensor

Fuel tank full

Fuel tank empty

Fuel gauge sensor

295 ohms

52 ohms

NOTE:

To check the resistance values "full" or "empty", the fuel gauge sensor must be 
removed and the sensor float moved to the upper or lower stop. See FUEL 
GAUGE SENSOR, REMOVING AND INSTALLING .

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1438  1439  1440  1441   ..