Volkswagen New Beetle. Manual - part 1487

 

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

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  1485  1486  1487  1488   ..

 

 

Volkswagen New Beetle. Manual - part 1487

 

 

Fig. 10: Identifying 3217 Union Nut Spanner 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1332 Torque wrench (40-200 N.m) 

Fig. 11: Identifying V.A.G 1332 Torque Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

Requirements 

z

Fuel tank must only be a maximum 1/2 full.  

NOTE:

z

If necessary empty fuel tank with fuel extraction unit VAS 5190  

z

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

 

2003 Volkswagen New Beetle GLS 

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

  

z

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

z

With ignition switched off disconnect battery Ground strap.  

z

Fold rear seat bench forward.  

z

Remove cover from fuel delivery unit.  

z

Disconnect 4-pin connector as well as supply and return lines from flange (arrows). 

Fig. 12: Disconnecting 4-Pin Connector, Supply And Return Lines From Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Seal lines to avoid contamination of fuel system.  

z

Remove union nut with spanner 3217. 

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.

NOTE:

Press buttons on hose couplings to disconnect.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 13: Removing Union Nut With Spanner
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

z

Pull fuel delivery unit and seal out of opening in fuel tank. 

Installing 

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

z

Adapt (match) engine control module to throttle valve control module. See COMPONENTS AND 
FUNCTIONS, ADAPTING
 .  

z

If fault memory has been erased or engine control module was disconnected from permanent positive, 

NOTE:

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

NOTE:

z

Insert seal for fuel delivery unit flange "dry" into opening of fuel tank.  

z

Moisten seal with fuel only when installing fuel delivery unit flange or fuel 
delivery unit.  

z

When inserting fuel delivery unit be careful to ensure that the fuel gauge 
sender does not become bent/deformed.  

z

Note installed position of flange of fuel delivery unit: Marking on flange 
must align with marking on fuel tank (arrows). 

Fig. 14: Connecting 4-Pin Connector, Supply And Return Lines From 
Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Ensure tight fit of fuel hoses.  

z

After installing the fuel delivery unit, check that the supply, return and vent 
lines are still clipped onto the fuel tank.  

 

2003 Volkswagen New Beetle GLS 

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

  

adapt respective components to engine control module (see COMPONENTS AND FUNCTIONS, 
ADAPTING
 ), and generate readiness code again.  

FUEL GAUGE SENDER, REMOVING AND INSTALLING 

Removing 

z

Install fuel delivery unit. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

z

Release and disconnect terminals for wires -3- and -4-.  

z

Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downward (arrows).  

Fig. 15: Removing And Installing Fuel Gauge Sender 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Installing 

z

Insert fuel gauge sender in guides on fuel delivery unit and push up until it engages.  

z

Install fuel delivery unit. See FUEL DELIVERY UNIT, REMOVING AND INSTALLING .  

FUEL TANK, REMOVING AND INSTALLING 

Special tools, equipment, testers, measuring instruments and auxiliary items required 

z

V.A.G 1383 A Engine/transmission jack 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

Content   ..  1485  1486  1487  1488   ..