Volkswagen New Beetle. Manual - part 1478

RULES FOR CLEANLINESS 

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

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Thoroughly clean all unions and 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!  

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Carefully cover opened components or seal if repairs cannot be carried out immediately.  

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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.).  

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

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Make sure that no diesel fuel runs onto the coolant hoses. Immediately clean any accidental hose 
contamination. Affected hoses must be replaced.  

FUEL COOLER, REMOVING AND INSTALLING 

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

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

Special tools and equipment 

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V.A.G 1331 Torque wrench (5 to 50 N.m)  

Fig. 5: Identifying Special Tools And Equipment (V.A.G 1331) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

NOTE:

The fuel cooler is located in the fuel return line to the tank. It is located on the 

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove cover -A-.  

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Separate fuel lines at fuel cooler. 

Fig. 6: Locating Fuel Cooler 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Remove securing nuts (arrows).  

Installing 

Installation is performed in the reverse sequence of removal. Note the following: 

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Tighten fuel cooler securing nuts to 20 N.m. 

Fig. 7: Removing Fuel Cooler Securing Nuts 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

vehicle underbody.

 

2003 Volkswagen New Beetle GLS 

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

  

FUEL DELIVERY UNIT, REMOVING AND INSTALLING

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

Observe rules for cleanliness, See RULES FOR CLEANLINESS . 

Special tools and equipment 

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3217 Ring nut wrench  

Fig. 8: Identifying Special Tools And Equipment (3217 Ring Nut Wrench) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

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

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With ignition switched off disconnect battery Ground (GND) strap.  

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Fold rear seat bench forward.  

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Remove cover from fuel delivery unit.  

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4-pin connector as well as supply and return lines must be disconnected from the fuel delivery unit. 

WARNING:

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The fuel and the fuel lines in the fuel system can become very hot 
(danger of scalding)!  

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The fuel system is also under pressure! Before opening the system, 
place cloths around the connections. Then carefully loosen the 
connection to release pressure  

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Wear eye and hand protection when performing any type of repair 
work on the fuel system!  

 

2003 Volkswagen New Beetle GLS 

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

  

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Remove union nut with wrench 3217.  

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Pull fuel gauge sensor and seal out of opening in fuel tank. 

Fig. 9: Removing Fuel Gauge Sensor Union Nut With Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

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

NOTE:

Press locking ring inward to release fuel lines.

NOTE:

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

NOTE:

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Do not bend fuel sensor when installing.  

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Insert fuel delivery unit seal dry into fuel tank opening.  

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Moisten inner edges of seal with fuel only when installing fuel delivery 
unit.  

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Note installation position of fuel gauge sensor: The marking on the fuel 
delivery unit must align with marking on fuel tank (arrows). 

 

2003 Volkswagen New Beetle GLS 

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