Volkswagen New Beetle. Manual - part 1492

 

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Volkswagen New Beetle. Manual - part 1492

 

 

Fig. 38: Removing Breather Valve Cover Cap Screw 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Screw adapter V.A.G 1318/20-1 onto adapter V.A.G 1318/20. 

Fig. 39: Identifying V.A.G. 1318/20-1 & V.A.G. 1318/20 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Turn valve (at T-piece) counterclockwise until it is completely open.  

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Screw adapter V.A.G 1318/20 hand tight onto breather valve. 

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 40: Screwing Adapter V.A.G 1318/20 Hand Tight Onto Breather Valve 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Connect hose of diesel suction pump VAS 5226 as shown.  

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Turn valve (at T-piece) clockwise into breather valve onto limit stop.  

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Check adapters and hose connectors for leaks.  

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Operate remote control V.A.G 1348/3A until bubble-free fuel comes out of breather valve.  

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Turn valve (at T-piece) counterclockwise again until it is completely open.  

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Clamp-off hose of diesel suction pump VAS 5226 (e.g. with hose clamp 3094) and disconnect it from 
adapter V.A.G 1318/20-1.  

z

Unscrew adapter V.A.G 1318/20 from breather valve.  

ACCELERATOR MECHANISM, SERVICING 

ACCELERATOR MECHANISM, COMPONENT OVERVIEW (ENGINE CODE AEG) 

1. Accelerator cable 

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Adjusting. See ACCELERATOR CABLE, ADJUSTING  

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Do not reuse damaged accelerator cable, replace  

2. Retaining clip 

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Adjusting accelerator cable. See ACCELERATOR CABLE, ADJUSTING  

3. Vibration damper  

4. Accelerator pedal  

5. Spacer sleeve  

6. Bearing socket  

7. Washer  

8. Stop bolt  

NOTE:

The following list refers to items in Fig. 41 .

 

2003 Volkswagen New Beetle GLS 

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

  

9. 20 N.m 

Fig. 41: Exploded View Of Accelerator Mechanism 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

ACCELERATOR CABLE, ADJUSTING (ENGINE CODE AEG) 

Vehicles with manual transmission 

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

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V.A.G 1788/10 Engine speed regulator  

Fig. 42: Identifying V.A.G 1788/10 Engine Speed Regulator 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

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Hook accelerator cable into accelerator pedal and cam plate of throttle valve control module. 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Pull off retaining clip for accelerator cable.  

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Depress accelerator pedal fully to wide open throttle position. 

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Adjust accelerator cable by moving retainer on support bracket, so that wide open throttle position is 
attained on cam plate of throttle valve control module.  

Vehicles with automatic transmission 

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

z

V.A.G 1788/10 Engine speed regulator  

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Hand multimeter V.A.G 1526 A or multimeter V.A.G 1715  

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Adapter set V.A.G 1594 

Fig. 43: Identifying Special Tools 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

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Adjust accelerator cable by moving retainer on support bracket so that wide open throttle position is 
attained on cam plate of throttle valve control module.  

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Release accelerator pedal.  

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Pull 2-pin connector off Kick down switch -F8- in front engine compartment (on bulkhead).  

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Connect hand multimeter V.A.G 1526 A with auxiliary cables from V.A.G 1594 to kick down switch. 

NOTE:

Assistance of a second technician is required or support accelerator pedal 
against steering wheel using V.A.G 1788/10 speed regulator.

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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