Volkswagen New Beetle. Manual - part 1458

 

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Volkswagen New Beetle. Manual - part 1458

 

 

Fig. 2: Identifying Installation Position Of Fuel Delivery Unit Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Marking on sensor must align with the marking on fuel tank -arrows-. 

Blue or blue marked return pipe -1- to connection with identification -R-. 

Black supply pipe -2- to connection with identification -V-. 

Checking Change-Over Valve 

Fig. 3: Checking Change-Over Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Valve in rest position: Closed 

NOTE:

After installing fuel delivery unit flange, check that the supply, return and 
breather pipes are still clipped onto the fuel tank.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

Valve pushed in direction of arrow: Open 

Checking Pressure Retaining Valve 

Fig. 4: Checking Pressure Retaining Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Pressure retaining valve is open from EVAP canister and from Evaporative Emission (EVAP) Canister Purge 
Regulator Valve -N80- in both flow directions -arrow- -1-. 

From gravity valve side, it is only open in one flow direction -arrow- -2-. 

SAFETY PRECAUTIONS WHEN WORKING ON FUEL SUPPLY SYSTEM 

z

Route all sorts of hoses/lines (e.g. for fuel, hydraulics, evaporative emissions system, coolant, refrigerant, 
brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.  

z

Make sure sufficient clearance to all moving or hot components.  

When removing and installing the fuel gauge sensor or fuel pump (fuel delivery unit) from a full or partly full 
fuel tank the following must be observed: 

z

Before commencing work, switch on exhaust extraction system and place an extraction hose close to the 

NOTE:

Before installing change-over valve, unscrew cap from fuel tank.

CAUTION: When doing any repair work, especially in the engine compartment, due to 

the cramped conditions, pay attention to the following:

WARNING:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

sensor opening in the fuel tank to extract escaping gas fumes. If no exhaust extraction system is available, 
a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m

3

 /h can be used.  

z

Prevent skin contact with gasoline! Wear fuel resistant gloves!  

z

For safety reasons, remove fuse 28 from fuse holder before opening fuel system because fuel pump can 
be activated via driver side door contact switch. 

Fig. 5: Identifying Location Of Fuse 28 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RULES OF 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.  

z

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 carried out 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 and equipment 

z

VAG 1332 Torque wrench (40-200 N.m) 

NOTE:

Fuse box is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

Fig. 6: Identifying VAG 1332 Torque Wrench (40-200 N.m) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

3217 Ring nut wrench 

Fig. 7: Identifying 3217 Ring Nut Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

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

z

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

z

With ignition switched off disconnect battery Ground strap.  

z

Remove cover under bench seat.  

z

Pull 4-pin connector and supply and return pipes off flange. 

z

Remove union nut with 3217 wrench. 

WARNING:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

 

 

 

 

 

 

 

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