Volkswagen New Beetle. Manual - part 1488

 

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Volkswagen New Beetle. Manual - part 1488

 

 

Fig. 16: Identifying V.A.G 1383 A Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

V.A.G 1331 Torque wrench (5-50 N.m) 

Fig. 17: Identifying V.A.G. 1331 Torque 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 strap.  

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Open fuel flap.  

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Remove rear axle: 

NOTE:

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

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Fuel extraction unit VAS 5190 is recommended to empty the fuel tank.  

 

2003 Volkswagen New Beetle GLS 

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

  

See AXLE BEAM . 

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Remove right rear wheel housing liner: 

See REAR WHEEL HOUSINGS LINER, ASSEMBLY OVERVIEW . 

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Remove cover for fuel tank (arrows). 

Fig. 18: Removing Fuel Tank Cover 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Drain fuel tank, clean fuel filler neck and surrounding area.  

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Disconnect breather lines/hoses on filler neck.  

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Remove mounting screw and remove tank flap unit with rubber cup. 

See FUEL TANK FILLER FLAP UNIT, REMOVING AND INSTALLING . 

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Pull EVAP canister breather lines off.  

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Unhook gravity valve.  

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Remove securing bolt on filler neck.  

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Fold rear seat bench forward. 

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Remove cover from under fuel tank.  

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Remove cover from fuel delivery unit.  

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Remove 4-pin connector from flange (arrow). 

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)

  

Fig. 19: Removing 4-Pin Connector From Flange 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting 
point. 

Fig. 20: Disconnecting Return Hose, Supply Hose And Breather Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Seal lines to avoid contamination of fuel system.  

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Remove tensioning strap. When doing this support fuel tank with engine/transmission jack V.A.G 1383 
A.  

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 release.

 

2003 Volkswagen New Beetle GLS 

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

  

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Lower fuel tank. Guide breather hoses/lines through longitudinal member while lowering tank.  

Installing 

Install in reverse sequence. Note the following points:  

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Route breather and fuel hoses kink free.  

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Ensure tight fit of fuel hoses.  

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Guide breather hoses/lines through opening in longitudinal member (install line guide).  

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Secure breather hoses/lines to filler neck with spring-type clamp.  

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

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

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If fault memory has been erased or engine control module was disconnected from permanent positive, 
adapt respective components to engine control module (see COMPONENTS AND FUNCTIONS, 
ADAPTING
 ) and generate readiness code again.  

GROUND STRAP FOR REPLACEMENT FUEL TANKS, INSTALLING 

Condition 

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

Installing 

Install Ground strap Part No. 1J0 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 fuel gauge sender, check that the supply, return and breather 
lines 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.

NOTE:

Fig. 21 shows Ground strap already installed.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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