Volkswagen Fox (2004 year). Manual - part 21

Note

Always replace seals and gaskets.

– Drain the cooling system 

⇒ page 76

 .

– Remove Poly-V belt 

⇒ page 14

 .

– Remove timing belt 

⇒ page 41

 .

– Loosen securing bolts -1- and carefully remove the pump -2-.

1.6.2

Installing

The installation is carried out in removal reverse order, consider‐

ing the following:
– Moisten new O-ring -3- with coolant.
– Insert the pump -2- into engine block and tighten securing bolts

-1-. Tightening torque: 15 Nm.

Note

The pump plug must face downwards.

– Install and adjust timing belt 

⇒ page 41

 .

– Install Poly-V belt 

⇒ page 14

 .

– Fill cooling system 

⇒ page 76

 .

Fox 2004 ➤

1. Cooling system components - remove and install    

81

 

Special tools and workshop

equipment required
♦ Refractometer for cooling

system fluid analysis -

T10007-

♦ Tray -V.A.G 1306-
♦ Torque wrench - 5 to 50 Nm

( enc. 1/2") -VAG 1331-

♦ Standart-type clamp pliers -

VAS 5024A-

1.7.1

Removal

Note

Always replace seals and gaskets.

– Drain the cooling system 

⇒ page 76

 .

Fox 2004 ➤

82

 

– Rotate the thermostat -4- 

1

/4 of turn (90 °) to left and remove

it from connection flange -2-.

1.7.2

Installing

Installation is carried out by inverting the removal sequence, ob‐

serving the following:
– Moisten new O-ring -3- with coolant.
– Insert thermostat -4- into connection flange -2- and rotate 

1

/4

of turn (90°) to right.

Note

The support on the thermostat must be almost vertical.

– Mount the connection flange -2- with thermostat -4- into engine

block.

– Tighten securing bolts -1-. Tightening torque 15 Nm.
– Fill cooling system 

⇒ page 76

 .

Fox 2004 ➤

1. Cooling system components - remove and install    

83

 

Fuel supply system components - re‐

move and install

Note

♦

The hose connections are fastened by spring clamps or bra‐

ces.

♦

Always replace fastening clamps with spring-type clamps.

♦

To install spring clamps, we recommend using the Standart-

type clamp pliers -VAS 5024A- .

Follow safety measures 

⇒ page 88

 .

Observe rules for cleanliness 

⇒ page 88

 .

Repair fuel filter 

⇒ page 87

 .

Servicing accelerator mechanism 

⇒ page 94

 .

1.1

Fuel tank components with accessories - remove and install

1 - Securing clip
2 - Cover
3 - Sealing ring

❑ With rubber bellows.
❑ Remove and install.

4 - Securing bolt
5 - Fuel tank cover

❑ With rubber bellows.
❑ Remove and install ⇒ 

Rep. Gr.  55 .

6 - Vent valve

❑ Checking 

⇒ page 86

❑ To remove valve, open

the clip sideways to the

outside of the support.

❑ To remove and install,

remove the fuel filling

pipe.

7 - Gravity valve

❑ To remove, remove the

right rear wheel case

cover.

❑ To remove, release

locking tab and loosen

the valve upwards out of

filler nozzle.

❑ Check valve passage.

Vertical valve: open,

valve inclined at 45°:

closed.

Fox 2004 ➤

84