Volkswagen New Beetle. Manual - part 1486

 

  Index      Volkswagen     Volkswagen New Beetle 1998-2008 year - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1484  1485  1486  1487   ..

 

 

Volkswagen New Beetle. Manual - part 1486

 

 

Checking Pressure Retention Valve 

The pressure retention valve is opened in both through-flow directions from the gravity valve/pressure retention 
valve (arrow -1-). 

Fig. 6: Checking Pressure Retention Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is opened only in one through-flow direction from the EVAP system/solenoid valve junction piece (arrow -2-
). 

Checking direction of valve flow. See CHECKING DIRECTION OF VALVE FLOW . 

Checking direction of valve flow 

A. Union 1 1: 

z

Flow in both directions  

z

Union -2- is closed  

B. Union 1 - 2: 

z

Flow in both directions  

z

Union - 3 is closed  

C. Union 1 2: 

z

Flow in only one direction  

z

Union -3- is closed  

z

Valve must close when a vacuum is applied to union -1-

NOTE:

Before installing vent valve remove cap from fuel tank.

NOTE:

The following list refers to items in Fig. 6 .

 

2003 Volkswagen New Beetle GLS 

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

  

Installed Position Of Screw-Type Clamp For Fuel Filter

z

Install screw-type clamp (arrow) as shown in illustration. 

Ensure sufficient clearance between clamp fastener and fuel tank: 

Dimension "a" must be at least 5 mm 

Fig. 7: Identifying Installed Position Of Screw-Type Clamp For Fuel Filter 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing And Installing Fuel Pressure Regulator 

1. Fuel filter 

z

Arrows show flow direction  

2. Rubber hose  

3. Retaining clip 

z

Check if seated securely  

4. Ground strap 

z

Mounted on fuel filter retainer  

5. Supply pipe 

z

From fuel pump  

6. Return pipe 

z

To fuel pump  

7. Fuel pressure regulator 

NOTE:

The fuel filter is illustrated viewed from the front.

NOTE:

The following list refers to items in Fig. 8 .

 

2003 Volkswagen New Beetle GLS 

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

  

z

Checking. See FUEL PRESSURE REGULATOR AND HOLDING PRESSURE, 
CHECKING
 .  

8. Seal 

z

Replace  

9. O-ring 

z

Replace  

10. Supply pipe 

z

To union in fuel tank  

Fig. 8: Exploded View Of Fuel Filter & Fuel Pressure Regulator Assembly 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

SAFETY PRECAUTIONS WHEN WORKING ON THE FUEL SUPPLY SYSTEM 

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

z

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

CAUTION: When performing repair work, especially due to the confined conditions in 

the engine compartment, pay attention to the following: 

z

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, 
coolant, refrigerant, brake fluid and vacuum) as well as electrical 
wiring so that the original positions are restored.  

z

Ensure sufficient clearance to all moving or hot components.  

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)

  

sender opening in the fuel tank to extract escaping fuel fumes. If no exhaust extraction system is 
available, a radial fan with a displacement greater than 15 m3/h can be used (as long as motor is not in air 
flow).  

z

Prevent skin contact with fuel! Wear fuel-resistant gloves!  

z

For safety reasons, fuse No. 28 must be removed from fuse holder before opening fuel system because 
fuel pump can be activated by door contact switch in driver's door. 

Fig. 9: Locating Fuse Box (Behind Access Panel At Far Left End Of Dash) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

RULES FOR 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 performed 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, equipment, testers, measuring instruments and auxiliary items required 

z

3217 Union nut spanner 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1484  1485  1486  1487   ..