This DIY is for Removing and Replacing the Evaporation Canister
; however some of the steps in this DIY can be used to adjust, clean and/or replace the Fuel Door Actuator Cable.
If you are asking yourself the question below, then your problem might be the EVAP Canister; however the problem could be related to either of the three valves (Pressure Retention Valve, Gravity Valve, Switch Over Valve) connected to the filler neck. This DIY does not cover filler neck or fuel tank.
1) When I go to put gas in my car the fuel nozzle keeps shutting off?
This DIY Covers Model Years 1998 thru 2005.
I have been asked if there is/are alternative steps to this DIY; there are always alternatives, but according to Bentley, this is the better way to do it.
The author(s) assume that you (the reader) are reasonably capable with the automotive tools necessary to get the job accomplished, which means that you won’t glue your fingers together, then break something and then are smart enough to know not to try to blame or post ranting about anyone else if something goes horribly wrong because of it. AGREED?
These instructions were developed using the following NB's...
1) 1998 2.0 liter, 5 speed
As always, just remember to offer a simple thank you and credit to the original author if you pass on this information to friends and/or family!!
2 to 4 Hours; if you do not break anything.
A VW New Beetle Bentley Repair Manual or the Bentley DVD
or a Haynes manual.
Part cost varies, shipping and taxes not included ...
1) 2.0 Liter 1998 thru 2003 -- $423.94
2) 1.8 Liter Turbo 1999 thru 2003 -- $423.94
3) 2.0 Liter 2004 thru 2005 -- $620.44
4) 1.8 Liter Turbo 2004 thru 2005 -- $620.44
5) 2.5 Liter 2006 thru 2010 -- $620.44 -- (not covered in this DIY, just thought I would note it)
There are some White Plastic Tubes that are pressure seated onto their hose connections; if you damage one, the evaporation system may/will not work properly and you will get a CEL. If your state has emissions testing, you will not be able to pass.
You will be working under the car while it is on a jack or jack stand, so be sure and take the proper precautions to avoid an unwanted accident and try not to break anything or it will be costly to fix it.
Be sure to put the plastic wheel-well cover back in or the small debris that can be picked up by the tire during rotation will damage the EVAP system.
Be careful with all plastic, it will be brittle. If something does not move, look for the screw(s) that you missed? There will be several screws/bolts so do not loose any; I put mine in Ziploc bag(s) and label them.
So let’s begin...
The Yellow Rectangle in pic [EC 01] shows you the location of the EVAP Canister.