Volkswagen New Beetle. Manual - part 1449

 

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Volkswagen New Beetle. Manual - part 1449

 

 

adapt respective components to engine control module (see COMPONENTS AND FUNCTIONS, 
ADAPTING
 ), and generate readiness code again.  

FUEL GAUGE SENDER, REMOVING AND INSTALLING 

Removing 

z

Install fuel delivery unit. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

z

Release and disconnect terminals for wires -3- and -4-.  

z

Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downward (arrows).  

Fig. 15: Removing And Installing Fuel Gauge Sender 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

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

z

Install fuel delivery unit. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

FUEL TANK, REMOVING AND INSTALLING 

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

z

V.A.G 1383 A Engine/transmission jack 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 16: Identifying V.A.G 1383 A Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1331 Torque wrench (5-50 N.m) 

Fig. 17: Identifying V.A.G. 1331 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

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

z

With ignition switched off disconnect battery Ground strap.  

z

Open fuel flap.  

z

Remove rear axle: 

NOTE:

z

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

z

Fuel extraction unit VAS 5190 is recommended to empty the fuel tank.  

 

2003 Volkswagen New Beetle GLS 

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

  

See AXLE BEAM . 

z

Remove right rear wheel housing liner: 

See REAR WHEEL HOUSINGS LINER, ASSEMBLY OVERVIEW . 

z

Remove cover for fuel tank (arrows). 

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

z

Drain fuel tank, clean fuel filler neck and surrounding area.  

z

Disconnect breather lines/hoses on filler neck.  

z

Remove mounting screw and remove tank flap unit with rubber cup. 

See FUEL TANK FILLER FLAP UNIT, REMOVING AND INSTALLING . 

z

Pull EVAP canister breather lines off.  

z

Unhook gravity valve.  

z

Remove securing bolt on filler neck.  

z

Fold rear seat bench forward. 

z

Remove cover from under fuel tank.  

z

Remove cover from fuel delivery unit.  

z

Remove 4-pin connector from flange (arrow). 

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.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 19: Removing 4-Pin Connector From Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting 
point. 

Fig. 20: Disconnecting Return Hose, Supply Hose And Breather Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Seal lines to avoid contamination of fuel system.  

z

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

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 release.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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