Volkswagen New Beetle. Manual - part 1476

 

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Volkswagen New Beetle. Manual - part 1476

 

 

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Check wires for short to one another, to vehicle Ground and to battery positive (+). 

Specification: "INFINITE" ohms 

If wiring OK 

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Replace Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- 

See Engine Control Module (ECM), Replacing . 

THROTTLE POSITION SENSOR, ADJUSTING 

(with sensor removed) 

Adjusting cable cam 

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Install cable disc in specific location 

Fig. 18: Identifying Adjusting Cable Cam 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Attach Throttle Position (TP) sensor (with preassembled cable cam) to mounting block.  

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Reconnect TP sensor 6-pin harness connector.  

Fine adjustment with sensor installed 

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Depress accelerator pedal by hand until accelerator pedal lies against accelerator pedal stop. 

If accelerator pedal stop is not obtained or the pressure point of the kickdown switch can not be felt:

NOTE:

For vehicles with automatic transmission: the pressure point or stop from 
the kick down switch must be felt before Wide Open Throttle is reached.

 

2003 Volkswagen New Beetle GLS 

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

  

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Turn sensor in bracket slots.  

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After adjusting TP sensor, check TP sensor function using VAG 1551/1552 Scan Tool. See THROTTLE 
POSITION SENSOR, CHECKING 

 

2003 Volkswagen New Beetle GLS 

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

  

1998-2004 ENGINE

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

FUEL SUPPLY SYSTEM COMPONENTS, REMOVING AND INSTALLING 

Servicing fuel filter, See FUEL FILTER, SERVICING . 

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

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

Servicing accelerator mechanism, See ACCELERATOR MECHANISM, SERVICING . 

FUEL TANK, REMOVING AND INSTALLING 

1. Cap  

2. Seal 

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Replace if damaged  

3. 1 N.m  

4. Tank flap unit 

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With rubber cup  

5. Ground connection  

6. O-ring 

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Always replace  

7. Vent valve 

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To remove valve unclip sideways out of support  

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Remove cap item 1 before installing  

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Checking, See Fig. 3 .  

8. 6 N.m  

9. Protective cover 

NOTE:

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Hose connections are secured with either spring-type or clamp-type clips. 

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Always replace clamp-type clips with spring-type clips.  

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Fuel hoses in the engine compartment must be secured only with spring-
type clips. The use of clamp or screw-type clips is not permitted.  

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Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended 
for installing spring-type clips.  

NOTE:

The following list refers to items in Fig. 1 .

 

2003 Volkswagen New Beetle GLS 

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

  

 

2003 Volkswagen New Beetle GLS 

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

  

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For filler neck  

10. Vent line 

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Check for secure seating  

11. Clamping washer  

12. Heat shield  

13. Fuel tank cover  

14. 20 N.m plus an additional 90° (1/4 turn) 

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Always replace  

15. Mounting strap 

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Note different lengths  

16. Fuel tank 

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When removing, support with engine/transmission jack V.A.G 1383 A  

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Removing and installing, See FUEL TANK, REMOVING AND INSTALLING  

17. Seal 

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Replace if damaged  

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When installing, insert seal "dry" into fuel tank opening  

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Moisten inner edges of seal with fuel when installing fuel gauge sensor  

18. Fuel gauge sensor 

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Observe installed position on fuel tank, See Fig. 2  

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Removing and installing, See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

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Check fuel gauge signal sensor, See FUEL GAUGE SENSOR, CHECKING  

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Check fuel pump. See FUEL PUMP, CHECKING ELECTRICALLY and DELIVERY 
PRESSURE AND DELIVERY RATE OF FUEL PUMP, CHECKING
 .  

19. Union nut 

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Remove and install with key 3217  

20. Supply line 

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Black  

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To fuel filter, See FUEL FILTER, SERVICING  

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Clipped onto fuel tank  

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Check for secure seating  

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Press locking ring inward to release fuel line of fuel gauge sensor  

21. Return hose 

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Blue  

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From fuel cooler, See FUEL COOLER, REMOVING AND INSTALLING  

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Clipped onto fuel tank  

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Check for secure seating  

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Press locking ring inward to release fuel line of fuel gauge sensor 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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