Volkswagen New Beetle. Manual - part 1623

 

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Volkswagen New Beetle. Manual - part 1623

 

 

z

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

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

If the holding pressure drops below 2 bar: 

z

Start engine and run at idle speed.  

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Switch ignition off after pressure has built-up. At same time close pressure measured device cut-off tap 
(handle cross through -flow direction -arrow-). 

Fig. 91: Identifying Pressure Gauge 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Observe pressure drop on gauge.  

If the pressure does not drop: 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Check fuel pump non -return valve.  

See CHECK FUEL PUMP 

If the pressure drops again: 

z

Open VAG 1318 pressure gauge shut-off tap (handle in through - flow direction). 

Fig. 92: Checking Pressure Gauge For Leaks 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Start engine and run at idle speed.  

z

Switch ignition off after pressure has built-up. At same time pinch/seal return hose together.  

If the pressure does not drop: 

 

2003 Volkswagen New Beetle GLS 

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

  

z

Replace fuel pressure regulator, see item 4 . 

If the pressure drops again: 

z

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

z

Check pressure gauge for leaks.  

Intake air system (unmetered air), checking for leaks 

Checking with engine leak detector spray G 001 800 A1 

Special tools, test equipment and auxiliary items 

z

VAG 1551 scan tool or VAG 1552 mobile scan tool with VAG 1551/3B cable  

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Engine leak detector spray G 001 800 A1  

Test conditions 

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Engine Coolant Temperature (ECT) must be at least 80 °C, display group 04, display zone 3.  

Test sequence 

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Connect VAG 1551 scan tool (or VAG 1552). Start engine and select "Address word" 01 of Motronic 
Engine Control Module (ECM) -J220-. Engine must be running at idle speed. Connecting scan tool and 
selecting Motronic Engine Control Module (ECM) -J220-, see VAG 1551, CONNECTING AND 
SELECTING MOTRONIC ENGINE CONTROL MODULE (ECM) -J220-
 .  

Indicated on display 

NOTE:

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

NOTE:

z

The vacuum in the intake system will cause the leak detector spray to be 
drawn in with the unmetered air. The leak detector spray reduces the 
combustibility of the mixture. This leads to a drop in engine speed and to a 
change of oxygen sensor reading.  

z

The safety precautions listed on the container must be adhered to.  

 

2003 Volkswagen New Beetle GLS 

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

  

Fig. 93: Identifying Scan Tool Display - Checking For Unmetered Air Leaks (1 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press buttons -0- and -8- for function "Read measuring value block" and confirm entry with -Q- button. 

Indicated on display 

Fig. 94: Identifying Scan Tool Display - Checking For Unmetered Air Leaks (2 Of 3) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Press buttons -0-, -0- and -1- for "Display group number 1" and confirm entry with -Q- button. 

Indicated on display (1 to 4 Display zones)

 

2003 Volkswagen New Beetle GLS 

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

  

 

 

 

 

 

 

 

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