Volkswagen Fox (2004 year). Manual - part 22

⇒ page 88

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11 - 26 ± 3 Nm
12 - Vent hose

❑ Check that it is securely connected.

13 - Vent hose

❑ To gravity valve.
❑ Check that it is securely connected.

14 - Bearing
15 - Expansion tank
16 - Fuel pump

❑ Check the flange installation position in the fuel tank 

⇒ page 86

❑ Remove and install 

⇒ page 91

 .

❑ Check fuel pump 

⇒ page 92

 .

❑ With fuel gauge sensor -G-.
❑ Remove and install fuel meter sensor 

⇒ page 92

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❑ Clean strainer if soiled.

17 - Sealing ring

❑ Replace if damaged.
❑ Moisten with fuel when installing the pump.

18 - Circlip

❑ Remove and install with Spanner -VW 5321/9-

19 - Supply tube

❑ To fuel filter 

⇒ Item 1 (page 87)

 .

❑ Secured with clip to the fuel tank.
❑ Check that it is securely connected.
❑ Black.
❑ Press the release button in the connection piece for removing the flange.

20 - Return pipe

❑ Blue or blue marked.
❑ Secured with clip to the fuel tank.
❑ Check that it is securely connected.
❑ To remove the flange, press the release button in the connection piece.

Fox 2004 ➤

1. Fuel supply system components - remove and install     

85

 

mark -R-.
Black supply pipe -2- connected to connection with mark -V-.

Note

After fuel pump flange installation, check if supply, return and vent

pipes are still fastened to fuel tank.

Check vent valve
Lever in rest position: closed.
Lever pushed in the direction of arrow: open.

Note

Before vent valve installation, remove fuel tank cover.

Fox 2004 ➤

86

 

1 - Supply tube

❑ From the fuel tank.
❑ White or with white

marking.

❑ Check that it is securely

connected.

2 - Return pipe

❑ Blue or blue marked.
❑ Check that it is securely

connected.

3 - Control valve

❑ Assembly position: the

arrow must point to fuel

tank.

❑ When replacing the fil‐

ter, remove the fasten‐

ing clip and completely

remove the control

valve along with the fuel

pipes.

❑ Below +15 °C: Passage

to filter open.

❑ Over +31 °C: Passage

to filter closed.

4 - Supply tube

❑ To auxiliary pump.
❑ Check that it is securely

connected.

❑ White or with white

marking.

5 - Return pipe

❑ From auxiliary pump.
❑ Check it is securely

seated.

❑ Blue or blue marked.

6 - Fuel pipe
7 - Cooling system hose
8 - Fuel temperature sensor -G81-
9 - Cooling system hose
10 - Fuel filter

❑ Fill with diesel before installing.
❑ Flow direction is identified with an arrow.
❑ Do not interchange the connections.
❑ Replace if damaged.

Fox 2004 ➤

1. Fuel supply system components - remove and install     

87

 

supply system

WARNING

During assembly work especially within the engine compart‐

ment, due to the lack of space, bear in mind the following:

♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter

system, cooling system and cooling gas, brake fluid, vac‐

uum) and electric cables must be restored to their original

positions.

♦ To provide easy access to all the moving or hot parts.

When removing or installing fuel level sensor or fuel pump, with

fuel tank full or partially full, observe the following:
When removing or installing fuel level sensor or fuel pump, in the

fuel tank full or partially full, observe the following:

WARNING

♦ The fuel and hoses in the fuel system may be very hot

( risk of burns)!

♦ Fuel system is under pressure!
♦ Use protective gloves and eyewear when carrying out any

repairs to the fuel system!

♦ Before starting installation work, place a gas exhaust hose of

a switched on gas exhaust system near the fuel tank opening,

so as to absorb gases released by the fuel. If exhaust equi‐

ment is unavailable use a radial fan ( the motor must be out of

air flow) with air movement rate higher than 15 m

3

/ hour.

♦ Avoid skin contact with fuel! Use fuel resistant gloves!

1.4

Cleanliness rules

For jobs on the fuel / injection system, strictly observe the follow‐

ing “6 cleaning” rules:
♦ Carefully clean all the connections and surrounding areas be‐

fore disconnecting them.

♦ Place all the parts removed on clean surface and cover them.

Do not use cloth that releases lint!

♦ If repair work is not to be carried out immediately, open com‐

ponents must be covered up or carefully preserved.

♦ Install only clean components. Only remove spare parts from

packaging just prior to installation. Do not install components

that have been kept out of packaging (i.e. inside the tool box,

etc.).

♦ With system open: If possible, avoid using compressed air. If

possible, do not move the vehicle.

♦ Also, ensure that no diesel runs onto the cooling system ho‐

ses. Hoses that may come into contact with fuel must be

cleaned immediately. Damaged hoses should be replaced.

1.5

Fuel tank - remove and install

Special tools and workshop equipment required

Fox 2004 ➤

88