Volkswagen New Beetle. Manual - part 1490

 

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Volkswagen New Beetle. Manual - part 1490

 

 

connector. 

Fig. 27: Connecting Diode Test Lamp To Outer Contacts Of 4-Pin Connector 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Operate remote control. LED must light up.  

LED does not light up: 

z

Locate and eliminate open circuit referring to current flow diagram: 

See appropriate SYSTEM WIRING DIAGRAMS article. 

LED lights up (voltage supply OK): 

z

Remove union nut with spanner 3217. 

Fig. 28: Removing Union Nut With Spanner 
Courtesy of VOLKSWAGEN OF AMERICA, INC.

 

2003 Volkswagen New Beetle GLS 

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

  

z

Check that electrical wires between flange and fuel pump are connected.  

If no open circuit can be found: 

z

Fuel pump faulty, replace fuel delivery unit. See FUEL DELIVERY UNIT, REMOVING AND 
INSTALLING
 .  

Checking delivery rate 

Requirements 

z

Voltage supply OK  

z

Remote control V.A.G 1348/3A connected  

Work sequence 

z

Remove filler cap from fuel tank filler neck. 

z

Pull off supply hose -3- (with white marking) (engine codes BEV, BGD: black markings) and collect fuel 
that leaks out with a cloth. 

Fig. 29: Removing Fuel Supply Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Connect pressure gauge V.A.G 1318 with adapter V.A.G 1318/23 and V.A.G 1318/17 to fuel supply line. 

WARNING:

The fuel system is under pressure! Before opening the system place 
a cloth around the connection. Then release pressure by carefully 
loosening the connection.

NOTE:

Press locking ring inward to release fuel line.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 30: Connect Pressure Gauge To Fuel Supply Line 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Push hose V.A.G 1318/16 onto adapter V.A.G 1318/11 on pressure gauge and hold hose in a measuring 
container.  

z

Open shut-off tap on pressure gauge. Lever then points in flow direction -A-.  

z

Operate remote control V.A.G 1348/3A. Close cut-off tap slowly, until pressure gauge shows 3 bar 
(except engine codes BEV and BGD). From now on do not alter setting of cut-off tap. 

For engine codes BEV and BGD: 3.5 bar 

z

Empty measuring container.  

The quantity of fuel delivered by the fuel pump depends on the battery voltage. Therefore: 

z

Connect multimeter to vehicle battery using adapter cables from V.A.G 1594 A.  

z

Operate remote control for 30 seconds and measure battery voltage.  

z

Compare quantity of fuel delivered with nominal value. 

*) Minimum delivery cm

3

 /30 seconds 

 

**) Voltage at fuel pump with engine at rest and pump running (approx. 2 volts less than battery 
voltage).  

NOTE:

The following list refers to items in Fig. 31 .

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 31: Fuel Pump Delivery Reference Graph 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Example: During the test, a voltage of 12.5 volts is measured on the battery. As the voltage at the pump is 
approx. 2 volts less than the battery voltage, the result is a minimum delivery of 200 cm

3

 /30 s. 

If the minimum delivery rate is not attained: 

z

Check fuel lines for possible restrictions (kinks) or blockages.  

z

Pull fuel line -1- off input side of fuel filter. 

Fig. 32: Connecting Pressure Gauge With Adapter 1318/17 To Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Connect pressure gauge V.A.G 1318 with adapter 1318/17 to hose.  

z

Repeat delivery rate check.  

NOTE:

Press locking ring inward to release fuel line.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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