Get Supplysystem-tank,Fuelpump(pre-supplypump)G6 -> 1 Fuel supply system components - remove and install Guide for 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 with_ls_kpring 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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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

FOX 2004 ➤

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.

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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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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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

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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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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

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

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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

65

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ 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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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

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.

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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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FOX 2004 ➤

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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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

FOX 2004 ➤

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

69

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ 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 .

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– Check the Fuel pump relay -J17- : ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations

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Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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 ➤

3 - Cyl. injection engine - Edition 12.2009

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

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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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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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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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FOX 2004 ➤

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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

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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

FOX 2004 ➤

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).

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– 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

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

75

Supplysystem-tank,Fuelpump(pre-supplypump)G6 -> 1 Fuel supply system components - remove and install for Your Volkswagen Fox SUV Second Generation (2003-2021)

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