Volkswagen New Beetle. Manual - part 1444

 

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Volkswagen New Beetle. Manual - part 1444

 

 

Fig. 31: Identifying Special Tools And Equipment (VAS 5187 Pressure Gauge) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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

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VAS 5051 Vehicle diagnostic, testing and information system with diagnostic cable VAS 5051/5A or 
VAS 5051/6A 

Fig. 32: Identifying Special Tools And Equipment (V.A.G 1331 Torque Wrench) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

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Coolant temperature at least 85 C  

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Unit injectors OK  

Work sequence 

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Unscrew sealing plug (arrow). 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 33: Unscrew Sealing Plug On Tamdem Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect pressure gauge VAS 5187 as shown in Fig. 34 . 

Fig. 34: Connecting VAS 5187 Pressure Gauge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Start engine and run at idling speed.  

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Connect vehicle diagnostic, test and information system VAS 5051 and select operating mode "vehicle 
self-diagnosis". Enter control module engine electronics with address word "01".  

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Select diagnostic function "08-Read measured value block".  

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Enter via number keys display group "2" and confirm with Q key.  

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Read idling speed in display zone 1.  

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Increase engine speed to above 1500 rpm.  

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Observe indicated pressure on gauge. 

Specification: at least 3.5 bar. 

 

2003 Volkswagen New Beetle GLS 

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

  

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Press <--key.  

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Press function 06-"End output".  

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Switch ignition off.  

If specification is not obtained: 

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Replace tandem pump. See TANDEM PUMP, REMOVING AND INSTALLING . 

TANDEM PUMP, REMOVING AND INSTALLING 

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

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

Special tools and equipment 

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

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V.A.G 1390 Vacuum pump  

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V.A.G 1390/1 Fluid receptacle  

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V.A.G 1921 Pliers for spring-type hose clips or VAS 5024 Assembly tool for spring-type clips 

Fig. 35: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

NOTE:

Tighten the sealing plug to 25 N.m after having removed the pressure 
gauge. Always replace the sealing ring.

WARNING:

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The fuel and the fuel lines in the fuel system can become very hot 

 

2003 Volkswagen New Beetle GLS 

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

  

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Pull supply hose -1- (white marking) and return hose -2- (blue marking) off fuel lines on cylinder head.  

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Attach hand vacuum pump V.A.G 1390 with bleed bottle V.A.G 1390/1 to return hose -3-. 

Fig. 36: Attaching Hand Vacuum Pump V.A.G 1390 With Bleed Bottle V.A.G 1390/1 To Return 
Hose
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Operate hand vacuum pump until no fuel is coming out of return hose. Observe that no fuel is siphoned 
into hand vacuum pump.  

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Remove vacuum hose -1 - from brake booster of tandem pump -4-.  

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Remove supply hose -2- (white marking) from tandem pump -4-.  

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Remove securing bolts (arrow).  

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Remove tandem pump -4- from cylinder head.  

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Pull tandem pump -4- upward slightly, pull return hose -3- off (blue marking) and remove tandem pump -
4-. 

(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!  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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