Volkswagen New Beetle. Manual - part 1586

 

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Volkswagen New Beetle. Manual - part 1586

 

 

Fig. 44: Disconnecting Fuel Return Hose And Fuel Supply Hose (Engine Code BDC)
Courtesy of VOLKSWAGEN OF AMERICA, INC.
 

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Connect pressure gauge V.A.G 1318 to fuel supply line/hose and to hose to fuel rail using adapters 
1318/9 and 1318/17. 

Fig. 45: Connecting Pressure Gauge V.A.G 1318 To Fuel Supply Line/Hose And Hose To Fuel Rail 
Using Adapters 1318/9 And 1318/17
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Open shut-off tap on pressure gauge. Handle points in direction of flow.  

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Reinstall fuse 28 (fuel pump) in fuse holder.  

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Start engine and run at idling speed.  

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Measure fuel pressure. 

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Specification: Approx. 2.5 bar  

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Pull vacuum hose -1- off fuel pressure regulator -2-. 

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Fuel pressure must increase to approx. 3.0 bar 

NOTE:

Press locking ring inward to release fuel line.

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 46: Removing Vacuum Hose Off Fuel Pressure Regulator 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

If the specification is not obtained: 

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Check delivery rate of fuel pump. See FUEL PUMP, CHECKING  

If the specification is obtained: 

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Switch off ignition.  

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Check for leaks and holding pressure. Watch pressure drop on gauge. 

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

If the holding pressure drops below 2 bar: 

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Start engine and run at idling speed.  

 

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

Fig. 47: Closing Pressure Gauge V.A.G 1318 Cut-Off Tap 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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Observe pressure drop on gauge.  

If the pressure does not drop: 

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

If the pressure drops again: 

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Check pressure gauge for leaks.  

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

If no leaks can be found: 

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Replace fuel pressure regulator  

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Erase fault memory to return learned values to a neutral (default) position. See ENGINE CONTROL 
MODULE FAULT MEMORY, INTERROGATING AND ERASING
 .  

Engine codes BEV, BGD 

NOTE:

Place a cloth around the connections to be loosened again and remove fuse 28 
(fuel pump) from fuse holder before removing the pressure gauge.

NOTE:

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The fuel pressure regulator regulates the fuel pressure to approx. 4 bar.  

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The fuel pressure regulator is located at the fuel filter (next to the fuel 
tank).  

 

2003 Volkswagen New Beetle GLS 

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

  

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

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V.A.G1318 Pressure gauge  

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1318/9 Adapter  

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1318/17 Adapter  

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1318/23 Adapter  

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V.A.G 1348/3 A Remote control 

Fig. 48: Identifying Special Tools, Equipment, Testers And Measuring Instruments (Engine Codes 
BEV And BGD)
 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Work sequence 

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Remove cover in front of fuse holder.  

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Remove fuse 28 (fuel pump) from fuse holder. 

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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