Volkswagen New Beetle. Manual - part 1585

 

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Volkswagen New Beetle. Manual - part 1585

 

 

If the specification is not obtained: 

z

Check quantity supplied by fuel pump. See FUEL PUMP, CHECKING  

If the specification is obtained: 

z

Switch off ignition.  

z

Check for leaks and holding pressure by observing pressure drop on gauge. 

z

After 10 minutes there must be a residual pressure of at least 2.0 bar  

If the holding pressure drops below 2.0 bar: 

z

Start engine and run at idle speed.  

z

Switch ignition off after pressure has built-up. Simultaneously, close pressure measured device V.A.G 
1318 cut-off tap. Handle is across through-flow direction (arrow). 

Fig. 39: Closing Pressure Measuring Device V.A.G 1318 Cut-Off Tap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Observe pressure drop on gauge.  

If the pressure does not drop: 

z

Check fuel pump non-return valve. See FUEL PUMP, CHECKING  

If the pressure drops again: 

z

Open pressure tester V.A.G 1318 shut-off tap. Handle is in through-flow direction. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 40: Opening Pressure Tester V.A.G 1318 Shut-Off Tap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Start engine and run at idle speed.  

z

Switch ignition off after pressure has built-up. Simultaneously, pinch/seal return hose -2- together. 

Fig. 41: Locating Fuel Return Hose 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the pressure does not drop: 

z

Replace fuel pressure regulator  

z

Erase DTC memory to put learned values in a neutral setting. See ENGINE CONTROL MODULE 
FAULT MEMORY, INTERROGATING AND ERASING
  

If the pressure drops again: 

z

Check line connections, O-rings on fuel manifold and injectors for leaks.  

z

Check pressure gauge for leaks.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

If a leak is repaired on vehicle: 

z

Erase DTC memory to put learned values in a neutral setting. See ENGINE CONTROL MODULE 
FAULT MEMORY, INTERROGATING AND ERASING
  

Engine code BDC 

The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure. 

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

z

V.A.G1318 Pressure gauge  

z

1318/9 Adapter  

z

1318/17 Adapter 

Fig. 42: Identifying Special Tools, Equipment, Tester And Measuring Instruments (Engine Code 
BDC)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

z

Remove fuse 28 (fuel pump) from fuse holder. 

NOTE:

Before removing the pressure gauge, remove fuse 28 again and place a cloth 
around the connections to be loosened.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

Fig. 43: Identifying Fuse 28 (Fuel Pump) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Disconnect following hose connections and collect fluids that may leak out with a cloth: 

2 - Fuel return hose (with blue markings) 

3 - Fuel supply hose (with white markings) 

NOTE:

Removing fuse 28 interrupts the voltage supply to the fuel pump for 
reasons of safety, otherwise it is possible that the fuel pump will be 
activated when opening the driver's door. Fuse holder is behind access 
panel at far left end of dash.

WARNING:

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

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Multiport Fuel Injection (MFI) - New Beetle, 2.0L (AEG, AVH, AZG, BDC, BEV & BGD)

  

 

 

 

 

 

 

 

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