Volkswagen New Beetle. Manual - part 1757

 

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Volkswagen New Beetle. Manual - part 1757

 

 

FUEL SYSTEM 

FUEL DELIVERY & SYSTEM PRESSURES 

Visual Fuel Leak 

Check for any visibly obvious signs of fuel leaks around engine, (i.e., look for clean areas on or near injection 
pump, injectors, and lines).  

FUEL FILTER 

Ensure fuel filter is not plugged. Place drain pan under fuel filter. With engine off, open drain valve on bottom 
of fuel filter until clean diesel fuel flows from drain tube. Close drain valve. It may be necessary to replace fuel 
filter if filter contains excessive water (replace filter if it contains more than half its capacity in water).  

FUEL PUMP 

This system is NOT equipped with an in-tank fuel pump. Diesel injection pump draws fuel directly from fuel 
tank.  

Maximum Variation Between Cylinders 

73 psi (5.0 bar) 

(1)

Operate starter until tester shows no further increase.

WARNING:

High fuel pressure may be present in fuel lines and component parts. 
Relieve pressure before attempting to open system for testing or 
component replacement. DO NOT allow fuel to flow onto engine or 
electrical parts or allow an open flame in area while testing fuel system 
components. DO NOT allow fuel to contact coolant hoses. 

NOTE:

Any fault pertaining to the fuel injection pump and fuel injection pump 
components will set DTCs. See appropriate SELF-DIAGNOSTICS article in 
ENGINE PERFORMANCE. 

 

2003 Volkswagen New Beetle GLS 

2000-2003 ENGINE PERFORMANCE Basic Diagnostic Procedures - Beetle, Diesel

  

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2003 ENGINE PERFORMANCE 

Emission Applications 

EMISSION APPLICATIONS 

2003 VOLKSWAGEN 

NOTE:

Always refer to Emission Control label in engine compartment before 
attempting service. If manual and Emission Control label differ, always use 
information provided on Emission Control label. 

Model, Engine & 
Fuel System 

(1)

Emission Control Systems & Devices 

Beetle 

1.8L 4-Cyl. Turbo 
SFI (Engine Code 
AWV) 

PCV, EVAP, TWC, FR, SPK, AIS, 

(2)

 HO2S EVAP-CPRV, 

EVAP-CKV, 

(3)

 EVAP-LDP, EVAP-LDPAF, EVAP-VC, FCOV, 

FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM, AIS-SV 

1.9L 4-Cyl. Turbo 
Diesel DFI 
(Engine Code 
ALH) 

PVC, OC, EGR, CEC, MIL,

(4)

 PCV-HE, FGOV, EGR-CKV, 

EGR-CLR, EGR-VRSV 

2.0L 4-Cyl. SFI 
(Engine Codes 
AVH & AZG) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL,

(4)

 

PVC-HE, CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM 

EuroVan 

2.8L VR6 SFI 
(Engine Code 
AXK) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL,

(4)

 

PCV-HE, EVAP-CKV, EVAP-CPRV, EVAP-CPSV, 

(3)

 EVAP-

LDP, EVAP-VC, FCOV, FGOV, FGVV, FTCV, FTVPRV, 

FTVPV, SPK-CC, AIS-CV, AIS-PM, AIS-SV, 

Golf 

1.9L 4-Cyl. Turbo 
Diesel DFI 
(Engine Code 
ALH) 

PVC, OC, EGR, CEC, MIL,

(4)

 PCV-HE, FGOV, EGR-CKV, 

EGR-CLR, EGR-VRSV 

2.0L 4-Cyl. SFI 
(Engine Codes 
AVH & AZG) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL,

(4)

 

PCV-HE, CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM 

2.0L 4-Cyl. SFI 
(Engine Code 
BBW) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(6)

 HO2S, CEC, MIL,

(4)

 

PCV-HE, CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-PM 

GTI 

1.8L 4-Cyl. Turbo 

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Emission Applications

  

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Emission Applications

  

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SFI (Engine Code 
AWP) 

PCV, EVAP, TWC, FR, SPK, AIS, 

(2)

 HO2S EVAP-CPRV, 

EVAP-CKV, 

(3)

 EVAP-LDP, EVAP-LDPAF, EVAP-VC, FCOV, 

FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM, AIS-SV 

2.8L VR6 SFI 
(Engine Code 
BDF) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL, 

CB, 

(4)

 PVC-HE, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-IMCV, AIS-

CV, AIS-PM, AIS-SV 

Jetta 

1.8L 4-Cyl. Turbo 
SFI (Engine Code 
AWP) 

PCV, EVAP, TWC, FR, SPK, AIS, 

(2)

 HO2S EVAP-CPRV, 

EVAP-CKV, 

(3)

 EVAP-LDP, EVAP-LDPAF, EVAP-VC, FCOV, 

FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM, AIS-SV 

1.9L 4-Cyl. Turbo 
Diesel DFI 
(Engine Code 
ALH) 

PVC, OC, EGR, CEC, MIL,

(4)

 PCV-HE, FGOV, EGR-CKV, 

EGR-CLR, EGR-VRSV 

2.0L 4-Cyl. SFI 
(Engine Codes 
AVH & AZG) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL,

(4)

 

PCV-HE, CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM 

2.0L 4-Cyl. SFI 
(Engine Codes 
BBW) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(6)

 HO2S, CEC, MIL,

(4)

 

PCV-HE, CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM 

2.8L VR6 SFI 
(Engine Code 
BDF) 

PCV, EVAP, TWC, FR, SPK, 

(5)

 AIS, 

(2)

 HO2S, CEC, MIL, 

CB, 

(4)

 PVC-HE, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-

PM, AIS-SV 

Passat 

1.8L 4-Cyl. Turbo 
SFI (Engine Code 
AWM) 

PCV, EVAP, TWC, FR, SPK, AIS, 

(2)

 HO2S, CEC, MIL, 

CB, EVAP-CPRV, EVAP-CKV, 

(3)

 EVAP-LDP, EVAP-LDPAF, 

EVAP-VC, FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-

PM, AIS-SV 

2.8L V6 SFI 
(Engine Code 
ATQ) 

PCV, EVAP, 

(7)

 TWC, FR, SPK, 

(5)

 AIS, 

(8)

 HO2S, CEC, MIL, 

CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, EVAP-VC, 

FCOV, FGOV, FTVPRV, SPK-CC, AIS-CV, AIS-PM, AIS-SV 

4.0L V8 SFI 
(Engine Code 
BDP) 

PCV, EVAP, 

(7)

 TWC, FR, SPK, 

(5)

 AIS, 

(8)

 HO2S, CEC, MIL, 

CB, EVAP-CPRV, 

(3)

 EVAP-LDP, EVAP-LDPAF, EVAP-VC, 

FCOV, FGOV, SPK-CC, AIS-PM, AIS-CV, AIS-SV 

(1)

For quick reference, major emission control systems and devices are listed in bold 
type; components and other related devices are listed in light type.

(2)

Engine uses two oxygen sensors.

Leak detection pump is located below right rear wheel housing liner.

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Emission Applications

  

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ABBREVIATIONS 

AIS  

Air Injection System  

AIS-CV  

AIS Combination Valve  

AIS-PM  

AIS Pump Motor  

AIS-SV  

AIS Solenoid Valve  

CB  

Crankcase Breather  

CEC  

Computerized Engine Controls  

DFI  

Diesel Fuel Injection  

EGR  

Exhaust Gas Recirculation  

EGR-CKV  

(3)

(4)

Mounted on side of air intake hose between air intake hose and PCV valve hose.

(5)

May also be referred to as secondary air injection system.

(6)

Engine uses three oxygen sensors and one exhaust gas temperature sensor.

(7)

Vehicle is equipped with two catalytic converters.

(8)

Engine uses four oxygen sensors.

 

2003 Volkswagen New Beetle GLS 

2003 ENGINE PERFORMANCE Emission Applications

  

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