Volkswagen New Beetle. Manual - part 1752

 

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Volkswagen New Beetle. Manual - part 1752

 

 

Fig. 8: Fuel Pressure Test Gauge (Lever In Closed Position) 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

8. If residual fuel pressure does NOT drop, check fuel pump check valve. See FUEL PUMP CHECK 

VALVE . If residual pressure drops again, go to next step.  

9. Open fuel pressure gauge shut-off handle to allow fuel flow. Start engine and run at idle speed. After fuel 

pressure has built up, turn ignition off. At same time pinch/seal fuel return line together.  

10. If fuel pressure does NOT drop, replace faulty fuel pressure regulator. If fuel pressure drops again, check 

fuel lines, connections and "O" rings for leaks. Check pressure gauge for leaks. Check for leaking fuel 
injectors. Perform fuel injector leak test. See appropriate SYSTEM & COMPONENT TESTING article.  

FUEL PRESSURE SPECIFICATIONS (1.8L TURBO & 2.0L) 

Function 

psi (bar) 

System Pressure (Except 2.0L - Engine Codes BEV & BGD) 

With Engine Idling 

(1)

36 (2.5) 

With Engine Idling 

(2)

44 (3.0) 

Residual Pressure 

(3)

29 (2.0) 

System Pressure (2.0L - Engine Codes BEV & BGD) 

With Engine Idling 

(1)

58 (4.0) 

Residual Pressure 

(3)

29 (2.0) 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

Page 10 

© 2004 Mitchell Repair Information Company, LLC. 

Fuel Pressure Test (2.0L - Engine Codes AEG, AVH & AZG) 

1. For engine identification, see IDENTIFICATION . Ensure engine is off. Ensure battery voltage is at 

least 12 volts. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .  

2.  

Connect Pressure Gauge (VAG 1318), or equivalent, at fuel supply line/hose in engine compartment. See 
Fig. 9 and Fig. 10 . Open shut-off valve of fuel pressure gauge; lever points in the direction of flow.  

3. Reinstall fuel pump (No. 28) fuse in dash fuse box.  

4. Start engine and idle. Fuel pressure should be within specification. See FUEL PRESSURE 

SPECIFICATIONS (1.8L TURBO & 2.0L) table. Continue to idle engine. Disconnect vacuum line 
from fuel pressure regulator on fuel rail. See Fig. 11 . Fuel pressure should be within specification.  

5. If fuel pressure is not as specified, check fuel pump volume. See FUEL PUMP VOLUME CHECK 

(EXCEPT 2.0L ENGINE CODES BEV & BGD) . If fuel pressures are okay, go to next step.  

6.  

Perform fuel system residual pressure test. Reinstall vacuum hose on fuel pressure regulator and continue 
to run engine at idle. Turn engine off. Check for fuel leaks. Check residual fuel pressure after 10 minutes. 
See FUEL PRESSURE SPECIFICATIONS (1.8L TURBO & 2.0L) table. If residual pressure drops 
below specification, start engine and run at idle speed.  

7. Switch ignition off after pressure has built up. At same time, close pressure gauge cut-off handle (handle 

at 90 degrees to fuel flow direction). See Fig. 8 . Gauge will now read fuel isolated in fuel rail.  

8. If residual fuel pressure does NOT drop, check fuel pump check valve. See FUEL PUMP CHECK 

VALVE . If residual pressure drops again, go to next step.  

9. Open fuel pressure gauge shut-off handle to allow fuel flow. Start engine and run at idle speed. After fuel 

pressure has built up, turn ignition off. At same time pinch/seal fuel return line together. See Fig. 9 .  

10. If fuel pressure does NOT drop, replace faulty fuel pressure regulator. If fuel pressure drops again, check 

fuel lines, connections and "O" rings for leaks. Check pressure gauge for leaks. Check for leaking fuel 
injectors. Perform fuel injector leak test. See appropriate SYSTEM & COMPONENT TESTING article. 

(1)

With fuel pressure regulator vacuum hose connected.

(2)

With fuel pressure regulator vacuum hose disconnected.

(3)

Minimum pressure after 10 minutes. If fuel system has passed this test, fuel pump 
check valve is okay.

NOTE:

Fuel pressure tester must be installed with the shut-off valve between the 
fuel supply line and the gauge for proper evaluation of residual pressure 
tests. 

NOTE:

Fuel system residual pressure (holding pressure) test checks integrity of 
fuel lines, fuel fittings, fuel pressure regulator, fuel injectors and fuel pump 
check valve. 

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

Page 11 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 9: Locating Fuel Supply/Return Lines (2.0L - Engine Codes AEG, AVH & AZG) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

Page 12 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 10: Connecting Fuel Pressure Test Gauge (2.0L - Engine Codes AEG, AVH & AZG) 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2003 ENGINE PEFORMANCE Basic Diagnostic Procedures - Beetle - Gasoline

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 8:43:29 AM

Page 13 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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