Volkswagen New Beetle. Manual - part 1442

 

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Volkswagen New Beetle. Manual - part 1442

 

 

Fig. 20: Identifying Special Tools And Equipment (V.A.G 1527 B Diode Test Lamp) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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V.A.G 1715 Multimeter  

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Wiring diagram 

Fig. 21: Identifying Special Tools And Equipment (V.A.G 1715 Multimeter) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Battery charge at least 11.5V  

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Fuses OK  

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All electrical consumers, e.g. lights and rear window defogger are switched off  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 22: Identifying Fuses (Behind Trim Panel On Far Left Side Of Dash) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Checking function and voltage supply 

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Remove cover from fuel gauge sensor.  

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Switch ignition on. Fuel pump must be heard to run for approx. 2 seconds.  

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Switch ignition off.  

If fuel pump does not run: 

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

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Connect diode test lamp V.A.G 1527 with adapter cables from V.A.G 1594 to outer contacts of 
connector. 

Fig. 23: Connecting Diode Test Lamp With Adapter Cables To Outer Contacts Of Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

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Switch ignition on. 

LED must light up for approx. 2 seconds. 

LED does not light up: 

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Check activation of fuel pump relay and check wiring for open and short circuit. 

See appropriate System Wiring Diagrams article. 

LED lights up (voltage supply OK.): 

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

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Check that electrical wires between flange and fuel pump are connected and for continuity.  

If no open circuit can be found: 

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Fuel pump faulty, replace fuel gauge sensor, See FUEL DELIVERY UNIT, REMOVING AND 
INSTALLING
 .  

Checking current draw of fuel pump 

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Disconnect 4-pin connector on fuel gauge sensor.  

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Set multimeter to measuring range 20 A and make a series connection between connector contacts -1- and 
fuel pump using adapter cables from V.A.G 1594 A. 

Fig. 24: Checking Current Draw Of Fuel Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

NOTE:

The current clamp of multimeter V.A.G 1715 can be connected between 
contacts -1- of connector and fuel pump, as an alternative solution.

 

2003 Volkswagen New Beetle GLS 

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

  

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Bridge contact -4- of connector and fuel pump using adapter cables from V.A.G 1594 A.  

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Start engine and run at idling speed.  

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Measure current draw of fuel pump. Specification: 3.5 to 4.5 Amps  

If the measured value is out of specification: 

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

DELIVERY PRESSURE AND DELIVERY RATE OF FUEL PUMP, CHECKING 

Special tools and equipment 

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3217 Ring nut wrench  

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V.A.G 1318 Pressure gauge  

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V.A.G 1318/1 Adapter  

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V.A.G 1318/11 Adapter  

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V.A.G 1318/17 Adapter  

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V.A.G 1318/23 Adapter 

Fig. 25: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

NOTE:

If irregularities occur when driving at high speed and: 

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no faults are stored in the control module DTC memory (see ENGINE 
CONTROL MODULE (DTC) MEMORY, READING AND ERASING ).  

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tandem pump is OK (See TANDEM PUMP, CHECKING )  

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and fuel filter change intervals are kept, 

the delivery pressure and delivery rate of fuel pump must be checked. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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