Volkswagen New Beetle. Manual - part 1448

 

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Volkswagen New Beetle. Manual - part 1448

 

 

sender opening in the fuel tank to extract escaping fuel fumes. If no exhaust extraction system is 
available, a radial fan with a displacement greater than 15 m3/h can be used (as long as motor is not in air 
flow).  

z

Prevent skin contact with fuel! Wear fuel-resistant gloves!  

z

For safety reasons, fuse No. 28 must be removed from fuse holder before opening fuel system because 
fuel pump can be activated by door contact switch in driver's door. 

Fig. 9: Locating Fuse Box (Behind Access Panel At Far Left End Of Dash) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RULES FOR CLEANLINESS 

When working on the fuel supply/injection system, pay careful attention to the following 5 rules: 

z

Thoroughly clean all unions and the adjacent areas before disconnecting.  

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Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

z

Carefully cover opened components or seal, if the repair cannot be performed immediately.  

z

Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.).  

z

When the system is open: Do not work with compressed air if this can be avoided. Do not move vehicle 
unless absolutely necessary.  

FUEL DELIVERY UNIT, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

3217 Union nut spanner 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 10: Identifying 3217 Union Nut Spanner 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1332 Torque wrench (40-200 N.m) 

Fig. 11: Identifying V.A.G 1332 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

Requirements 

z

Fuel tank must only be a maximum 1/2 full.  

NOTE:

z

If necessary empty fuel tank with fuel extraction unit VAS 5190  

z

Observe safety precautions before starting work. See SAFETY 
PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM .  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

z

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

z

With ignition switched off disconnect battery Ground strap.  

z

Fold rear seat bench forward.  

z

Remove cover from fuel delivery unit.  

z

Disconnect 4-pin connector as well as supply and return lines from flange (arrows). 

Fig. 12: Disconnecting 4-Pin Connector, Supply And Return Lines From Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Seal lines to avoid contamination of fuel system.  

z

Remove union nut with spanner 3217. 

WARNING:

Fuel supply lines are under pressure! Before removing a hose connection 
wrap a cloth around the connection. Then release pressure by carefully 
pulling the hose off the connection.

NOTE:

Press buttons on hose couplings to disconnect.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 13: Removing Union Nut With Spanner
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

z

Pull fuel delivery unit and seal out of opening in fuel tank. 

Installing 

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

z

Adapt (match) engine control module to throttle valve control module. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 .  

z

If fault memory has been erased or engine control module was disconnected from permanent positive, 

NOTE:

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

NOTE:

z

Insert seal for fuel delivery unit flange "dry" into opening of fuel tank.  

z

Moisten seal with fuel only when installing fuel delivery unit flange or fuel 
delivery unit.  

z

When inserting fuel delivery unit be careful to ensure that the fuel gauge 
sender does not become bent/deformed.  

z

Note installed position of flange of fuel delivery unit: Marking on flange 
must align with marking on fuel tank (arrows). 

Fig. 14: Connecting 4-Pin Connector, Supply And Return Lines From 
Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Ensure tight fit of fuel hoses.  

z

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel Supply - 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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