Volkswagen New Beetle. Manual - part 1441

 

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Volkswagen New Beetle. Manual - part 1441

 

 

Special tools and equipment 

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V.A.G 1331 Torque wrench (5 to 50 N.m) 

Fig. 15: Identifying Special Tools And Equipment (V.A.G 1331 Torque Wrench) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1383 A Engine/transmission jack  

Fig. 16: Identifying Special Tools And Equipment (V.A.G 1383 A Engine/Transmission Jack) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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Open fuel flap.  

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Check whether a coded radio is installed. If so, obtain anti-theft coding.  

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With ignition switched off disconnect battery Ground (GND) strap.  

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Remove tank flap unit with rubber cup. 

 

2003 Volkswagen New Beetle GLS 

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

  

See FUEL TANK FILLER FLAP UNIT, REMOVING AND INSTALLING . 

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Fold rear bench seat forward.  

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Remove cover from fuel gauge sensor and separate connection.  

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Remove rear axle: 

See AXLE BEAM . 

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Remove rear right wheelhouse liner: 

See REAR WHEEL HOUSINGS LINER, ASSEMBLY OVERVIEW . 

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Unscrew protective cover -1- (arrows). 

Fig. 17: Unscrew Protective Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove cover for fuel tank (arrows). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 18: Removing Fuel Tank Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drain fuel tank and clean area of fuel filler neck (unscrew filler cap).  

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Disconnect breather lines/hoses on filler neck.  

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Remove gravity valve from its retainer.  

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Remove mounting screws on filler neck. 

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Disconnect supply and return lines on right front of fuel tank. 

WARNING:

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The fuel and the fuel lines in the fuel system can become very 
hot (danger of scalding)!  

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The fuel system is also under pressure! Before opening the 
system, place cloths around the connections. Then carefully 
loosen the connection to release pressure.  

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Wear eye and hand protection when performing any type of 
repair work on the fuel system!  

NOTE:

Press locking ring inward to release fuel lines (arrows).

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 19: Disconnecting Supply And Return Lines On Right Front Of Fuel Tank 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Seal lines so that fuel system is not contaminated by dirt etc.  

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

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Lower fuel tank. Guide vent hoses/lines through longitudinal member.  

Installing 

Installation is performed in the reverse order. Note the following: 

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Route breather and fuel lines free of kinks.  

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Make sure fuel lines/hoses are installed securely.  

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Guide vent hoses/lines through opening in longitudinal member (install line guide).  

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Secure breather hoses/lines to filler neck with spring-type clamps.  

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

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Clip supply and return line onto fuel tank.  

FUEL PUMP, CHECKING ELECTRICALLY 

Special tools and equipment 

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V.A.G 1527 B Diode test lamp 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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