Volkswagen New Beetle. Manual - part 1460

 

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Volkswagen New Beetle. Manual - part 1460

 

 

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Make sure fuel hoses are seated securely.  

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Secure fuel hoses with spring-type clamps.  

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Do not interchange supply and return hose (return hose blue or blue markings, supply hose black).  

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Check DTC memory. 

See Diagnostic Trouble Code (DTC) Memory, Checking And Erasing . 

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Read readiness code. 

See Readiness Code, Displaying . 

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Match engine electronics control module to throttle valve control module. 

See Engine Control Module (ECM) To Throttle Valve Control Module, Adapting . 

REPLACEMENT FUEL TANKS, INSTALLING GROUND STRAP 

Condition 

All replacement fuel tanks do not come with ground strap (wire) installed. 

Installing 

Install ground strap Part No. 1 J0 201 184 into replacement fuel tank as follows: 

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Remove fuel filler cap and observe cautions printed on cap.  

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Bend up tab on inside of fuel filler pipe as shown -arrow-. 

NOTE:

After installing the fuel gauge sensor, check that the supply, return and 
breather pipes are still clipped onto the fuel tank.

NOTE:

The ground strap must be installed into all replacement fuel tanks.

CAUTION: Part numbers are for reference only. Always check with your Parts Dept. 

for the latest parts information.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 14: Bending Up Tab On Inside Of Fuel Filler Pipe 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Insert end -A- of ground strap through slot in tab up to bend -B- at other end of strap. 

Fig. 15: Inserting End -A- Of Ground Strap Through Slot In Tab Up To Bend -B- At Other End Of 
Strap
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Bend down tab on inside of fuel filler pipe. This will secure strap to end of tab.  

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Reinstall fuel filler cap.  

CRASH FUEL SHUT-OFF 

Function 

Vehicles with an airbag are equipped with a crash fuel shut-off system. It reduces the danger of a fire in a crash 

NOTE:

Illustration shows ground strap already installed.

 

2003 Volkswagen New Beetle GLS 

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

  

as the fuel pump is switched off via the fuel pump relay.

Simultaneously this system provides an improved start for the engine. When the door is opened the fuel pump is 
activated for 2 seconds to build-up the pressure in fuel system. 

When opening the fuel system: 

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

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Check activation of fuel pump relay using wiring diagram and VAG1466 A: 

See appropriate WIRING DIAGRAM article 

FUEL PUMP, CHECKING 

Special tools and equipment 

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3217 Ring nut wrench  

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VAG 1348/3A Remote control with VAG 1348/3-2 adapter cable  

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VAG 1466 Test system  

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VAG 1527 BLED test light  

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VAG 1594 A Adapter set  

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VAG 1715 Multimeter 

Fig. 16: Identifying Special Tools And Equipment (1 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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VAG 1318 Pressure tester  

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VAG 1318/1 Adapter  

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VAG 1318/11 Adapter  

 

2003 Volkswagen New Beetle GLS 

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

  

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VAG 1318/17 Adapter  

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VAG 1318/23 Adapter  

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VAG 1332 Torque wrench (40-200 N.m)  

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Measuring container  

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Wiring diagram 

Fig. 17: Identifying Special Tools And Equipment (2 Of 2) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Test conditions 

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Battery voltage at least 11.5 V  

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Fuse No. 28 OK 

Fig. 18: Identifying Location Of Fuse No. 28 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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All electrical consumers, e.g. lights and rear window defroster must be switched off.  

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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