Volkswagen New Beetle. Manual - part 1595

Fig. 4: Disassembling Fuel Rail With Injectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Safety precautions 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be 
noted: 

z

For safety reasons the fuse No. 28 must be removed from the fuse holder before opening the fuel system, 
otherwise the fuel pump can be activated by the door terminal switch.  

z

Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.  

z

The ignition must be switched off before connecting or disconnecting injection or ignition system wiring 
or tester cables.  

Observe following if test and measuring instruments are required during a test drive: 

z

Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this 
location.  

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If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in 
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the 
airbag is triggered.  

If the engine is to be turned at starter speed, without starting: 

z

Disconnect all 4 -pin connectors -2- from power output stage for ignition coils -1-. 

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 PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Fig. 5: Disconnecting All Pin Connectors From Power Output Stage For Ignition Coils 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull fuse No. 32 out of fuse holder.  

NOTE:

Removing fuse 32 interrupts the voltage supply to the fuel injectors. Fuse 
holder is located behind access panel at far left end of dash.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle

  

Fig. 6: Removing Fuse 32 Interrupts Voltage Supply To Fuel Injectors 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Rules of cleanliness 

When working on the fuel supply/injection system, pay careful attention to the following 5 rules: 

z

Thoroughly clean all unions and the adjacent areas before disconnecting.  

z

Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!  

z

Carefully cover opened components or seal, if the repair cannot be carried out immediately.  

z

Only install clean components: Only unpack replacement parts immediately prior to installation. Do not 
use parts that have been stored loose (e.g. in tool boxes etc.). 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI) , 1.8L AWP, AWV - New Beetle