2003-2021 Volkswagen Fox SUV Supplysystem-tank,Fuelpump(pre-supplypump)G6 User Manual
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Supplysystem-tank,Fuelpump(pre-supplypump)G6 for Your Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
20 – Supply system - tank, Fuel pump (pre-supply pump) -  
G6-  
1
Fuel supply system components - re‐  
move and install  
Note  
♦ Always replace fastening clamps with spring clamps.  
♦ Fuel tubes in the engine may be fastened withlskpring clamps  
only. Using tightening clamps and bolted clamps is not al‐  
lowed.  
♦ To install spring clamps, we recommend using VAS 5024A or  
Standart-type clamp pliers -VW 5162- .  
Fuel supply system components - remove and install  
⇒ page 63 .  
Safety measures for working on the fuel supply system  
⇒ page 65 .  
Follow cleaning rules ⇒ page 65 .  
Fuel pump (pre-supply pump) -G6- - remove and install  
⇒ page 66 .  
Fuel level indicator sensor -G- - remove and install ⇒ page 67 .  
Fuel tank - remove and install ⇒ page 68 .  
Fuel shut off in case of accident ⇒ page 70 .  
Fuel pump (pre-supply pump) -G6- - check ⇒ page 71 .  
Supply system - drain the air ⇒ page 78 .  
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3 - Cyl. injection engine - Edition 12.2009  
1.1  
Fuel supply system components - remove and install  
1 - Fastening clip  
2 - Reservoir lid  
3 - Sealing ring  
❑ Replace if damaged.  
4 - Fastening screw  
5 - Fuel supply nozzle com‐  
partment cover  
❑ With rubber bellows.  
❑ Remove and install⇒  
Body - External assem‐  
bly works; Rep. Gr. 55 ;  
Hoods .  
6 - Vent valve  
7 - Gravity valve  
❑ Remove rear right  
wheel case protector.  
❑ Remove the cover from  
fuel tank nozzle com‐  
partment with bellows.  
❑ Check valve passage  
continuity. Perpendicu‐  
lar valve: open. Valve in‐  
clined 45°: closed.  
8 - Fuel supply tube  
9 - Spring clamp  
10 - Fuel reservoir  
❑ Remove using the En‐  
gine / gearbox or VAG  
1383A jack. -EQ 7081- .  
❑ Remove and install  
⇒ page 68 .  
11 - 23...29 Nm  
12 - Pipes  
❑ Anti-choke for fuel tank up to expansion tank.  
13 - Pipes  
❑ Venting for fuel tank up to expansion tank.  
14 - Bearing  
15 - Expansion reservoir  
16 - Pipes  
❑ Anti-choke for the fuel tank supply nozzle housing.  
17 - Pipes  
❑ Venting for the fuel tank supply nozzle housing.  
18 - Fuel pump (pre-supply pump) -G6-  
❑ Remove and install ⇒ page 66 .  
❑ Clean the filter, in case it is dirty.  
❑ Fuel pump (pre-supply pump) -G6- - check ⇒ page 71 .  
❑ Observe the flange installation position in the fuel tank ⇒ page 64  
1. Fuel supply system components - remove and install  
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19 - Sealing gasket Fuel pump (pre-supply pump) -G6-  
❑ Remove and install ⇒ page 66 .  
20 - Circlip (sliding)  
21 - Supply pipes  
❑ Black.  
❑ Make sure it is well fastened.  
❑ For fuel distributor.  
22 - Return pipes  
❑ Blue.  
❑ Fastened laterally to the fuel tank.  
❑ Make sure it is well fastened.  
1 - For the fuel tank supply noz‐  
zle housing.  
2 - For activated charcoal filter  
3 - For the fuel tank supply noz‐  
zle housing.  
4 - Expansion reservoir  
5 - For expansion tank  
6 - For expansion tank  
Installation position for Fuel pump (pre-supply pump) -G6-  
The -arrow- on the Fuel pump (pre-supply pump) -G6- shall match  
to that on the reservoir.  
Note  
After installing the Fuel pump (pre-supply pump) -G6- , check if  
supply, return and vent pipes are still fastened to the fuel tank.  
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FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
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.  
1.2  
Safety measures in fuel supply works  
WARNING  
Fuel supply tube is under pressure! Wear protective goggles  
and gloves to prevent injuries and avoid contact with the skin.  
Before loosening tube junctions, place a cloth around the union  
point. Then, eliminate pressure by pulling the tube carefully.  
Caution  
In all assembly works, especially in engine compartment, due  
lk  
to lack of space, consider the following:  
♦ All pipes (e.g. fuel, hydraulic, activated charcoal filter,  
cooling system and cooling gas, break fluid, vacuum) and  
electric cables must be restored to original interconnec‐  
tion.  
♦ Ensure enough space in relation to all moving or hot com‐  
ponents to avoid damages to the connections.  
When removing and installing Fuel pump (pre-supply pump) -G6-  
with fuel tank full or partially full, consider the following:  
♦ Before starting installation works, place near the fuel reservoir  
opening, a suction hose for extracting equipment in operation,  
to absorb gases released by the fuel. If extracting equipment  
is unavailable, use a radial fan (the engine must be out of air  
3
flow) with air movement rate higher than 15 m / hour.  
♦ Avoid skin contact with the fuel! Wear fuel resistant gloves!  
♦ For safety reasons, before opening the fuel system, remove  
fuse number 33 from fuse holder, as the Fuel pump (pre-sup‐  
ply pump) -G6- can be activated.  
1.3  
Cleaning rules  
To carry out fuel supply/injection works, consider the following “5  
cleaning” rules thoroughly:  
♦ Carefully clean union points and respective surrounding areas  
before disconnecting them.  
♦ Place parts on clean surface and cover them. Do not use cloth  
that releases lint!  
♦ Carefully cover or close open parts, in case repair is not carried  
out immediately.  
1. Fuel supply system components - remove and install  
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FOX 2004 ➤  
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♦ Install clean parts only: Remove parts from the packaging im‐  
mediately before installation. Do not use parts that have been  
kept out of the packaging (for example, in tool boxes).  
♦ With system open: Do not work wit compressed air. Do not  
move the vehicle.  
1.4  
Fuel pump (pre-supply pump) -G6- - re‐  
move and install  
Special tools and workshop equipment required  
♦ Spanner -VW 5321/9- or Spanner -T10334-  
♦ Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-  
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1.4.1  
Removal  
– Take safety precautions before starting removal works  
⇒ page 65 .  
– Follow cleaning rules ⇒ page 65 .  
– First, check if the vehicle has code radio; if so, check the re‐  
spective anti-theft code.  
– With ignition off, disconnect earth strap from Battery -A- .  
– Fold rear seat forwards.  
– Remove Fuel pump (pre-supply pump) -G6- access cover.  
WARNING  
Fuel supply hose is under pressure. Before loosening hose  
junctions, place a cloth around them. Next, eliminate pressure  
by removing hose carefully.  
– Remove return -1- and supply -2- pipes and connector -3- from  
Fuel pump (pre-supply pump) -G6- .  
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FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
The -arrows- shows the installation position of the Fuel pump (pre-  
supply pump) flange -G6- .  
Note  
To remove fuel hoses, press the safety key located under the  
connection.  
– Remove the lock with Wrench -VW 5321/9- or Wrench -  
T10334- .  
– Remove the Fuel pump (pre-supply pump) -G6- and the seal  
from the opening in the fuel tank.  
Note  
In case of replacing the Fuel pump (pre-supply pump) -G6- , emp‐  
ty the old Fuel pump (pre-supply pump) -G6- before disposing it.  
1.4.2  
Installation  
– Fuel pump (pre-supply pump) -G6- must be installed in the  
reverse sequence to the removal.  
lk  
Note  
♦ Try not to bend the Fuel level indicator sensor -G- during in‐  
stallation.  
♦ Install Fuel pump (pre-supply pump) -G6- sealing dry on fuel  
tank opening.  
♦ Lubricate the sealing with fuel only for installing the Fuel pump  
(pre-supply pump) -G6- .  
♦ Observe installation position of the Fuel pump (pre-supply  
pump) -G6- -arrow-.  
♦ The mark on the Fuel pump (pre-supply pump) -G6- shall  
match that on the body.  
♦ Check the firm seating of the fuel hoses.  
♦ Do not confuse the supply and return hoses.  
♦ After installation of the Fuel pump (pre-supply pump) -G6- ,  
check whether the supply, return and vent pipes are still fas‐  
tened to the fuel reservoir.  
1.5  
Fuel level sensor -G- - remove and in‐  
stall  
1.5.1  
Removal  
– Remove Fuel pump (pre-supply pump) -G6- ⇒ page 66 .  
1. Fuel supply system components - remove and install  
67  
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3 - Cyl. injection engine - Edition 12.2009  
– Disengage the connector from the Fuel level indicator sensor  
-G- by displacing the lock-1-and moving the connector in  
-arrow a-direction.  
– Press lock -2- and move the Fuel level indicator sensor -G- -3-  
upwards-arrow b-.  
1.5.2  
Installation  
– Position the Fuel level indicator sensor -G- on the Fuel pump  
(pre-supply pump) guides -G6- and press it downwards until it  
fits.  
– Install the Fuel level indicator sensor -G- connector.  
1.6  
Fuel reservoir - remove and install  
Special tools and workshop equipment required  
♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331-  
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3 - Cyl. injection engine - Edition 12.2009  
♦ Transmission jack or engine + transmission set -EQ 7081- or  
Transmission jack or engine + transmission set -VAG 1383A-  
♦ VAS 5024A or Standart-type clamp pliers -VW 5162-  
1.6.1  
Removal  
– Observe safety precautions before starting removal jobs  
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⇒ page 65 .  
– First, check if the vehicle has code radio; if so, check the re‐  
spective anti-theft code.  
– Remove the fuel reservoir lid.  
– With the ignition switched off, disconnect the Battery -A- earth  
strap.  
– Drain the fuel tank with Fuel absorption equipment - VAS  
5190- and clean around the fuel nozzle.  
– Fold rear seat forwards.  
– Remove Fuel pump (pre-supply pump) -G6- access cover.  
– Disengage the 4-pole connector from Fuel pump (pre-supply  
pump) -G6-  
– Remove fuel reservoir hoses next to the Fuel pump (pre-sup‐  
ply pump) -G6- .  
– Loosen exhaust system. The exhaust system must be fas‐  
tened to the body with wire, slightly lowered.  
– Remove heat deflector between the exhaust tube and the fuel  
tank.  
– Loosen fuel filter -1- supply hose.  
– Remove clamp from fuel supply tube near the tank with Stand‐  
art-type clamp pliers -VW 5162- or Standart-type clamp pliers  
-VAS 5024A- .  
– Remove fastening bolts, supporting the fuel tank with the En‐  
gine / gearbox jack -EQ 7081- or Engine / gearbox jack - VAG  
1383A- .  
– Lower fuel reservoir.  
WARNING  
Fuel supply hose is under pressure. Before loosening hose  
junctions, place a cloth around them. Next, eliminate pressure  
by removing hose carefully.  
1.6.2  
Installation  
Installation is carried out by reversing the removal sequence,  
considering the following:  
♦ Install vent and fuel hoses without bending them.  
1. Fuel supply system components - remove and install  
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FOX 2004 ➤  
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♦ Check the firm seating of the fuel hoses.  
♦ Do not invert supply and return hoses (return hose blue or with  
blue marking, supply hose black).  
Note  
♦ Once the fuel reservoir is installed, check if supply, return and  
ventilation hose sets are still fixed.  
♦ If fuel tank has been replaced, it is necessary to drain the air  
from the fuel system ⇒ page 68 .  
1.7  
Fuel shut off in case of accident  
1.7.1  
Operation  
The fuel is shut off in case of an accident in order to reduce risk  
of fire in the vehicle after a collision, in which the Fuel pump (pre-  
supply pump) -G6- is disconnected by the Fuel pump relay -J17- .  
At the same time, with this equipment, the engine starts more  
smoothly.  
When opening the fuel system, consider the following safety pre‐  
cautions ⇒ page 65 .  
lk  
– Check the Fuel pump relay -J17- : ⇒ Current flow diagrams,  
Electrical fault finding and Fitting locations  
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1.8  
Fuel pump (pre-supply pump) -G6- - check  
Special tools and workshop  
equipment required  
♦ Spanner -VW 5321/9- or  
Spanner -T10334-  
♦ Pressure gauge -VAG  
1318-  
♦ Adapter -VAG 1318/13-  
♦ Adapter -VAG 1318/11-  
♦ Adapter -VAG 1318/17-  
♦ Torque wrench - 40 to 200  
Nm (enc. 1/2") -VAG 1332-  
1. Fuel supply system components - remove and install  
71  
FOX 2004 ➤  
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Special tools and workshop  
equipment required  
♦ Adapting cable -VAG  
1348/3-2-  
♦ Test probe -EQ 7300- or  
Test probe -VAG 1527B-  
♦ Auxiliary measuring set -  
VAG 1594A -  
♦ Multimeter -VAG 1715-  
♦ -Recipiente graduado-  
♦ ⇒ Current flow diagrams,  
Electrical fault finding and  
Fitting locations  
1.8.1  
Check conditions  
•
•
•
Fuse number 33 ok.  
Battery -A- voltage must be at least 11.5 V.  
All power consuming components, like lights and rear window  
demister, must be off.  
•
If the vehicle is equipped with air conditioning, turn it off.  
Note  
Observe the description of how fuel is shut off in case of accident  
⇒ page 70 .  
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1.8.2  
Operation of power supply - check  
Note  
In the following operation sequence, it might be necessary to dis‐  
connect the Battery -A- earth strap. Therefore, check whether a  
code radio is fitted. If this is case, obtain the anti-theft code first.  
– Fold rear seat forwards.  
– Remove the cover beneath the seat.  
– Turn the ignition on. The Fuel pump (pre-supply pump) -G6-  
has to work audibly for approx. 1 second.  
If the Fuel pump (pre-supply pump) -G6- does not work:  
– Turn the ignition off.  
– Remove fuse holder cover.  
– Remove fuse 33 from the ( Fuel pump (pre-supply pump) -  
G6- ) fuse holder.  
– Connect the Remote control -VAG 1348/3A- and Adapter ca‐  
ble -VAG 1348/3-2- to the lower contact of fuse 33 for activat‐  
ing the Fuel pump (pre-supply pump) -G6- and to the positive  
terminal of Battery -A- (+).  
– Activate the Remote control -VAG 1348/3A- .  
If the Fuel pump (pre-supply pump) -G6- works:  
– Check operation of Fuel pump relay -J17- , according to ⇒ Cur‐  
rent flow diagrams, Electrical fault finding and Fitting locations.  
If the Fuel pump (pre-supply pump) -G6- does not work:  
– Disengage the 4-pole connector for the Fuel pump (pre-supply  
pump) -G6-  
– Connect the Test probe -EQ 7300- or Test probe -VAG 1527B-  
with Auxiliary cables -VAG 1594A- with Auxiliary cables to the  
connector external contacts.  
– Activate the Remote control -VAG 1348/3A- .  
The LED should light up.  
– If LED does not light up:  
– Locate and eliminate cable interruption, according to⇒ Current  
flow diagrams, Electrical fault finding and Fitting locations.  
The LED lights up (correct power supply):  
– Remove the Fuel pump (pre-supply pump) -G6- with the Span‐  
ner -VW 5321/9- or Spanner -T10334- .  
– Check that the cables are connected to the Fuel pump -G23- .  
In case there is no cable interruption:  
– Fuel pump (pre-supply pump) -G6- - damaged, replace.  
1. Fuel supply system components - remove and install  
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1.8.3  
1.8.4  
Fuel flow - check  
Test conditions  
•
•
•
Fuel pump (pre-supply pump) -G6- supply is ok.  
Remote control -VAG 1348/3A- installed.  
Fuel pump (pre-supply pump) -G6- pressure and fuel pressure  
adjuster OK: ⇒ page 98  
1.8.5  
Test sequence  
Note  
Fuel flow is measured at 3.0 bar for vehicles manufactured until  
lk  
May/2006, and 4.0 bar for vehicles produced as of June/2006.  
Thereby, fuel pressure must be checked before measuring the  
flow.  
– Remove the fuel reservoir lid.  
WARNING  
Fuel supply pipes are under pressure. Before loosening hose  
connection, place a cloth around them. Next, eliminate pres‐  
sure by removing hose carefully.  
– Disconnect fuel hose coupling-1- and clean the spilled fuel  
with a cloth.  
– Couple the Pressure gauge -VAG 1318 - to the fuel supply  
tube, by using the adapters Connector -VAG 1318/23- and  
Adapter -VAG 1318/17- .  
– Connect the Pressure gauge -VAG 1318- hose to the Adapter  
-VAG 1318/11- and Adapter -VAG 1318/1- on the checking  
Pressure gauge -VAG 1318- and place its end inside a grad‐  
uated container with at least 3.0-liter capacity.  
– Open the Pressure gauge -VAG 1318- valve. It will indicate  
the flow direction-A-.  
– Activate the Remote control -VAG 1348A- , closing the cock  
slowly, until the Pressure gauge -VAG 1318- indicates a pos‐  
itive pressure of 3.0 bar for vehicles manufactured until May/  
2006, and 4.0 bar for those produced as of June/2006. Then,  
do not change cock position.  
– Empty measuring container.  
– The Fuel pump (pre-supply pump) -G6- flow depends on the  
Battery voltage -A- . Because of that, couple the Multimeter -  
VAG 1715- to the vehicle Battery -A- , by using the Auxiliary  
cables -VAG 1594A- .  
– Activate the Remote control -VAG 1348A- for 30 seconds,  
measuring the Battery -A- voltage.  
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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6  
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3 - Cyl. injection engine - Edition 12.2009  
– Compare fuel flow with theoretical value for vehicles manu‐  
factured until May/2006 ( Fuel pump (pre-supply pump) -G6-  
pressure of 3 bar).  
lk  
– Compare fuel flow with theoretical value for vehicles manu‐  
factured as of June/2006 ( Fuel pump (pre-supply pump) -G6-  
pressure of 4 bar).  
3
6) Minimum amount cm /30 s  
7) Voltage in the Fuel pump (pre-supply pump) -G6- with engine stopped and  
Fuel pump (pre-supply pump) -G6- operating (approx. 2 volts less than Battery -  
A- voltage).  
Example of reading:  
During the test, a voltage of 12.5 volts is measured on the Battery  
-A- . As in the Fuel pump (pre-supply pump) -G6- there is a voltage  
of around 2 volts less than in the Battery -A- , the result is a min‐  
3
3
imum supply flow of 633 cm >/30 s for vehicles manufactured  
until May/2006 and 333 cm /30 s for vehicles produced as of  
June/2006.  
If minimum flow capacity is not reached:  
– Check if the supply pipes to the filter present folds or obstruc‐  
tions.  
If fuel pipes are ok.  
– Check fuel flow before fuel filter.  
WARNING  
Fuel supply pipes are under pressure! Before loosening hose  
connections, put a cleaning cloth on connection points. Then  
depressurize by carefully pulling the hose.  
Note  
For that, press the keys on hose connectors.  
1. Fuel supply system components - remove and install  
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FOX 2004 ➤  
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– Remove supply hose-1- from fuel filter inlet and connect it to  
Adapting set -VAG 1318/17- .  
– Pressure gauge -VAG 1318- with Adapting set -VAG 1318/17-  
as shown.  
– Install the adapter -V.A.G 1318/16- on the adapter -  
V.A.G 1318/11- for the Pressure gauge -VAG 1318- and put  
its end in a graduated container with at least 3.0-liter capacity.  
– Open the Pressure gauge -VAG 1318- valve. The cock points  
towards the fuel passage-A-.  
– Activate the Remote control -VAG 1348/3A- , closing the cock  
slowly, until the Pressure gauge -VAG 1318- indicates a pres‐  
sure of 3.0 bar for vehicles manufactured until May/2006, and  
4.0 bar for those produced as of June/2006. Do not change  
cock position.  
– Empty measuring container.  
– Check flow again.  
– Activate the Remote control -VAG 1348/3A - once more for 30  
seconds. Compare the flow value with the one obtained in the  
first measurement.  
If the minimum flow is reached:  
– Replace the fuel filter.  
If the minimum flow is not reached again:  
– Remove the Fuel pump (pre-supply pump) -G6- and check  
whether there is dirt in the screen filter.  
Only if no irregularities have been found so far:  
– Fuel pump (pre-supply pump) -G6- - damaged, replace it  
⇒ page 66 .  
If the desired fuel flow is reached, but at great cost, we may con‐  
clude that the fuel supply presents irregularities (i.e.: a momentary  
fault in the fuel supply):  
– Couple the removed fuel tubes again.  
– By using the current leakage clamp meter, couple the Multi‐  
meter -VAG 1715- to contact 1 (blue/white) 4-pole connection  
socket box cable -arrow- from cable harness.  
– Start engine and let it run in idle speed.  
– Measure current draw of the Fuel pump (pre-supply pump) -  
G6- .  
Theoretical value: 6.8 ampere at most for vehicles manufactured  
until May/2006 and 7.6 ampere for the ones produced as of June/  
2006.  
Note  
If it is a temporary fault in the fuel system, checking can also take  
place during a test drive, when the presence of a second person  
will be necessary.  
If the current draw is excessive:  
– Fuel pump (pre-supply pump) -G6- - damaged, replace it.  
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1.8.6  
1.8.7  
Fuel pump (pre-supply pump) -G6-  
check valve - check  
Test conditions  
•
Remote control -VAG 1348/3A- and Adapting cable -VAG  
1348/3-2- connected.  
1.8.8  
Test sequence  
lk  
WARNING  
Fuel supply pipes are under pressure! Before loosening hose  
connections, put a cleaning cloth on connection points. Then  
depressurize by carefully pulling the hose.  
Note  
This test must check simultaneously the tightness of joints on the  
fuel supply tube sets, from the Fuel pump (pre-supply pump) -G6-  
to the joint on the Pressure gauge -VAG 1318- .  
– Remove supply hose -1- from fuel filter inlet and connect it to  
the Adapting set -VAG 1318/17- and the Pressure gauge -  
VAG 1318- .  
– Install the Adapter -VAG 1318/16- on the Pressure gauge -  
VAG 1318/11- Adapter and insert the hose -VAG 1318- end  
in a measuring container.  
Note  
For that, press the keys on hose connectors.  
– Close the valve on the Pressure gauge -VAG 1318- (trans‐  
verse valve in relation to the flow direction - position -B-).  
– Activate the Remote control -VAG 1348/3A- in quick consec‐  
utive intervals, until reaching a pressure of approx. 3.0 bar for  
vehicles manufactured until May/2006 and 4.0 bar for the ones  
produced as of June/2006.  
WARNING  
Risk of splashing when opening the cock; keep a container in  
front of the free end of the Pressure gauge -VAG 1318- .  
– Eliminate eventual excess pressure by opening the valve  
carefully.  
– Check pressure drop on the Pressure gauge -VAG 1318- . Af‐  
ter 10 minutes, the pressure must not drop below 2.0 bar.  
If the pressure keeps dropping:  
– Check the joints for tightness.  
If no irregularities are found in the pipes:  
– Fuel pump (pre-supply pump) -G6- - damaged, replace it.  
1. Fuel supply system components - remove and install  
77  
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FOX 2004 ➤  
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1.9  
Supply system - drain the air  
Special tools and workshop  
equipment required  
♦ Remote control -VAG  
1348/3A- and Adapting ca‐  
ble -VAG 1348/3-2- con‐  
nected.  
♦ Gasoil aspirator -VAS  
5226-  
♦ Adapter -V.A.G 1318/20-  
♦ Adapter -V.A.G 1318/20-1-  
1.9.1  
Conditions  
•
•
•
The fuse must be ok.  
Battery -A- voltage must be at least 11.5 V.  
The Fuel pump relay -J17 - must be ok.  
1.9.2  
Operation sequence  
– Remove fuse holder cover.  
– Remove fuse 33 from the ( Fuel pump (pre-supply pump) -  
G6- ) fuse holder.  
78  
Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6  
FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
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– Connect the Remote control -VAG 1348/3A- and Adapter ca‐  
ble -VAG 1348/3-2- to the lower contact of fuse 33 for activat‐  
ing the Fuel pump (pre-supply pump) -G6- and to the positive  
terminal of Battery -A- (+).  
– Remove the protection cover -arrow- from the drainage valve.  
– Install the Adapter -VAG 1318/20-1- on the Adapter -VAG  
1318/20- .  
– Turn the valve (on T-part) counterclockwise until opening it  
completely.  
– Install the Adapter -VAG 1318/20- manually on the drainage  
valve.  
– Connect the Diesel aspirator -VAS 5226- tube, as illustrated.  
– Turn the valve (on T-part) clockwise up to the drainage valve  
stop.  
– Check the tube adapters and connections for leaks.  
– Activate the Remove control -VAG 1348/3A- until bubble-free  
fuel comes out of the drainage valve.  
– Turn the valve (on T-part) counterclockwise until opening it  
completely.  
– Strangle the Diesel aspirator - VAS 5226- hose (e.g. with up  
to Ø 25-mm tubing clamps -3094- ) and remove it from the  
Adapter -VAG 1318/20-1- .  
– Remove the Adapter -VAG 1318/20- from the drainage valve.  
1. Fuel supply system components - remove and install  
79  
FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
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2
Activated charcoal filter system  
Operation ⇒ page 80 .  
Activated charcoal filter system components - repair  
⇒ page 81 .  
Check fuel compartment ventilation ⇒ page 81 .  
2.1  
Operation  
Fuel vapours form over the fuel surface on the tank, depending  
on the atmospheric pressure and ambient temperature.  
The activated charcoal filter prevents these hydrocarbon emis‐  
sions from being released into the atmosphere.  
The fuel vapours coming from the highest point of the tank go  
through the gravity valve (which closes at a 45° inclination) and  
check valve, strangled in its amount, to the activated charcoal  
filter.  
The activated charcoal absorbs these vapours like a sponge.  
While driving and with Lambda adjustment active (hot engine),  
the electromagnetic valve 1 for activated charcoal filter system -  
N80- , (also known as regeneration valve) is activated cyclically  
by the Engine control unit -J623- , due to engine speed and load.  
The opening period depends on the input signals.  
Intake manifold vacuum aspirates fresh air through the vent open‐  
ing on the lower part of the activated charcoal filter, during the  
activated charcoal regeneration process. The fuel vapours stored  
in the activated charcoal and the fresh air are fed for combustion  
in dosed quantities.  
The pressure retention valve prevents the fuel vapours from being  
aspirated into the fuel reservoir, when the Magnetic valve I for  
activated charcoal filter -N80- is opened and there is vacuum in  
the intake manifold. This way, the activated charcoal filter regen‐  
eration is ensured.  
With no current (e.g., driver interruption) the Magnetic valve 1 for  
activated charcoal filter -N80- remains closed. The activated char‐  
coal filter will not be purged.  
Note  
♦ The flexible tube joints are fixed with a quick coupling.  
♦ Always replace fastening clamps with spring clamps.  
♦ To install spring clamps, we recommend using the Standart-  
type clamp pliers -VW 5162 - or Standart-type clamp pliers -  
VAS 5024A- .  
Follow safety measures ⇒ page 65 .  
Follow cleaning rules ⇒ page 65 .  
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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6  

Related Topics

1 Fuel supply system components - remove and install 1.1 Fuel supply system components - remove and install 1.2 Safety measures in fuel supply works 1.3 Cleaning rules 1.4 Fuel pump (pre-supply pump) G6 - remove and install 1.5 Fuel level sensor G - remove and install 1.6 Fuel reservoir - remove and install 1.7 Fuel shut off in case of accident 1.8 Fuel pump (pre-supply pump) G6 - check 1.9 Supply system - drain the air 2 Activated charcoal filter system 2.1 Operation 2.2 Activated charcoal filter system components - repair 2.3 Reservoir ventilation - check 3 Engine power electronic adjustment (electronic accelerator) 3.1 Operation 3.2 Engine power electronic adjustment (electronic accelerator)

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