Volkswagen Fox (2004 year). Manual - part 23

♦ Standart-type clamp pliers -VAS 5024A-

♦ Fuel extractor -VAS 5190-

1.5.1

Removal

– Follow safety precautions before starting work 

⇒ page 88

 .

– Follow cleanliness rules 

⇒ page 88

 .

– Check if the vehicle has code radio; if so, request respective

anti-theft code.

– With ignition switched off, disconnect battery earth strap.
– Fold rear seat forwards.
– Remove fuel pump access cover.

Fox 2004 ➤

1. Fuel supply system components - remove and install     

89

 

of burns)!

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

repairs on the fuel system!

– Drain fuel tank.
– Disconnect return -1- and supply -2- pipes, and the fuel tank

connector -3-.

Note

Press locks on pipe connectors to disconnect them.

– Exhaust system must be lowered a bit, and fastened to the

body with a metallic wire.

– Remove heat deflector between the exhaust tube and the fuel

tank.

– Remove fastening clips from the supply pipe by using the

Standart-type clamp pliers -VAS 5024A- .

– Support the fuel tank by using the Engine/gearbox combo jack

-VAG 1383A- .

– Remove fuel tank securing bolts.
– Lower fuel tank.

1.5.2

Installation

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

serving the following:
♦ Vent and fuel hoses are to be installed kink-free.
♦ Check the firm seating of the fuel hoses.
♦ Do not interchange supply and return lines (return hose blue

or with blue marking, supply line black).

Note

After installing fuel meter sensor, check that supply, return and

vent pipes are still fixed to the fuel tank.

Flange mark shall be aligned with fuel tank mark -arrow-.
Blue or blue marked return pipe -1- connected to connection with

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 fixed to fuel tank.

Fox 2004 ➤

90

 

Special tools and workshop equipment required
♦ Spanner -VW 5321/9- or Spanner -T10334-

♦ Torque wrench - 40 to 200 Nm ( enc. 1/2") -VAG 1332-

1.6.1

Removal

Follow safety measures 

⇒ page 88

 .

Follow cleanliness rules 

⇒ page 88

 .

– Check if the vehicle has code radio; if so, request respective

anti-theft code.

– With ignition off, disconnect earth strap from battery.
– Fold rear seat forwards.
– Remove fuel pump access cover.
– Disconnect return -1- and supply -2- pipes, and the fuel tank

connector -3-.

Note

Press locks on pipe connectors to disconnect them.

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 performing any

repairs on the fuel system!

Fox 2004 ➤

1. Fuel supply system components - remove and install     

91

 

– Remove fuel pump and seal fuel tank opening.

Note

When the fuel pump is to be replaced, drain it before discarding.

1.6.2

Installation

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

serving the following:

Note

♦

Do not fold fuel level sensor when installing.

♦

Insert flange sealing or the dry fuel pump into the fuel tank

opening.

♦

Moisten the seal with fuel only when installing the flange or

fuel pump.

♦

Make sure the fuel pipes are firmly seated.

♦

After installing the fuel pump flange, check whether the supply,

return and vent pipes are still fastened onto the fuel tank.

♦

Flange mark shall be aligned with fuel tank mark -arrow-.

1.7

Fuel meter sensor - remove and install

1.7.1

Removal

– Remove fuel pump 

⇒ page 91

 .

– Release and remove the terminals of the wires -3- and -4-.
– Raise retaining locks -1- and -2- with a screwdriver and pull

the fuel level sensor out and downwards -arrow-.

1.7.2

Installation

– Insert fuel level sensor in the fuel pump guides and push up

until it engages.

1.8

Fuel pump - check

Special tools and workshop equipment required

Fox 2004 ➤

92