Volkswagen New Beetle. Manual - part 1491

 

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Volkswagen New Beetle. Manual - part 1491

 

 

If the minimum delivery rate is now attained:

z

Replace fuel filter.  

If the minimum delivery rate is again not attained: 

z

Remove fuel delivery unit and check strainer for soiling.  

Only if no faults have been detected up to now: 

z

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

If the delivery rate has been attained but a fuel supply system fault (e.g. intermittent failure of fuel supply 
system) is still suspected: 

z

Check current draw of fuel pump as follows:  

z

Reconnect all disconnected fuel lines.  

z

Disconnect 4-pin connector from flange on fuel delivery unit.  

z

Set multimeter to measuring range 20 A and make a series connection between connector contacts -1- and 
fuel pump using adapter cables from V.A.G 1594 A. 

Fig. 33: Connecting Multimeter In Series Between Connector Contacts And Fuel Pump 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Bridge contact -4- of connector and fuel pump using adapter cables from V.A.G 1594 A.  

z

Start engine and run at idling speed.  

z

Measure current draw of fuel pump. 

NOTE:

The current clamp of multimeter V.A.G 1715 can be connected between 
contacts -1- of connector and fuel pump, as an alternative solution.

 

2003 Volkswagen New Beetle GLS 

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

  

Specification: max. 8 amps 

If the current draw is exceeded: 

z

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

Checking fuel pump non-return valve 

Requirements 

z

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

z

Pressure gauge V.A.G 1318 is still connected  

Work sequence 

z

Close pressure gauge cut-off tap (lever across flow direction, position -B-). 

Fig. 34: Checking Fuel System Pressure Drop 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Operate remote control at short intervals, until a pressure of approx. 3 bar has built up. 

NOTE:

If the fuel system malfunction is intermittent, perform the check during a 
road test with the help of a 2nd technician.

NOTE:

With this check the fuel supply line connections from the fuel delivery unit to 
the point at which the pressure gauge V.A.G 1318 is connected will be checked 
for leaks at the same time.

WARNING:

Danger of spray when opening the shut-off-tap; hold container in 
front of the free connection on the pressure gauge.

 

2003 Volkswagen New Beetle GLS 

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

  

z

If pressure builds up too high, lower excess pressure by carefully opening shut-off tap.  

z

Observe pressure drop on gauge. 

Over a duration of 10 minutes pressure must not drop below 2.5 bar 

If the pressure drops further: 

z

Check line connections for leaks.  

If no wiring fault is detected: 

z

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

FUEL SYSTEM, BLEEDING 

Engine codes BEV, BGD 

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

z

V.A.G 1348/3 A Remote control  

z

V.A.G 1348/3-2 Adapter cable  

z

VAS 5226 Diesel suction pump  

z

V.A.G 1318/20 Adapter  

z

V.A.G 1318/20-1 Adapter 

Fig. 35: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Requirements 

z

Fuses must be OK 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 36: Locating Fuses (Behind Access Panel At Far Left End Of Dash) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Battery voltage must be at least 11.5 V  

z

Fuel pump relay must be OK  

Work sequence 

z

Remove cover in front of fuse holder.  

z

Pull fuse No. 28 out of fuse holder.  

z

Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 to contact 28a to fuel pump 
and battery positive (+). 

Fig. 37: Connecting Remote Control V.A.G 1348/3A To Fuse Box Fuel Pump Contact 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove pressure hose from secondary air injection pump to combination valve.  

z

Unscrew cover cap (arrow) of breather valve. 

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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