The Volkswagen New Beetle is one of the many vehicles that mounts its electric fuel pump within the fuel tank. It is also a vehicle that provides access to the pump module from within the Beetle itself. The fuel pump cannot be separated from the module, so replacing it generally means you have to replace the entire module. This process won't require a lot of tools, but it does require caution due to the pressure the fuel system runs on.
Open the fuel cap on the side of the Beetle. Locate the fuse box and remove the number 28 fuse. Start the engine and wait for it to stall. Crank the engine for another three seconds to ensure there is no fuel pressure. Turn off the ignition and disconnect the negative battery terminal.
Push the front edge of the rear seat cushion where its clips are located to disengage the wires from the clips. Lift the seat up and remove it.
Detach the three screws for the fuel pump access cover with a Phillips screwdriver. Remove the cover.
Disconnect the pump's electrical connector. Press in the tabs on the fuel line fittings and disconnect them. The supply line has a black mark, and the return line has a blue mark.
Mark the fuel pump flange and the sealing surface with a marker to indicate the correct position of the pump module.
Loosen the pump's retaining ring with a large pair of water-pump pliers or a similar pair. Remove the pump module from the tank.
Clean off the sealing surface for the fuel pump with acetone and a rag.
Insert the replacement fuel pump module into the tank using the markings as your guide. Make sure it is completely seated. Tighten the ring with the same tool as before.
Attach the electrical connector and fuel lines. Make sure the supply and return lines connect to the right fittings.
Reconnect the pump access cover with its screws. Reinstall the rear seat cushion. Reconnect the negative battery terminal.
