Volkswagen Fox (2004 year). Manual — part 25
Special tools and workshop
equipment required
♦ Torque wrench - 5 to 50 Nm
(enc. 1/2") -VAG 1331-
♦ Vacuum pump -VAG 1390-
♦ Fluid container -
V.A.G 1390/1-
♦ Standart-type clamp pliers -
VAS 5024A-
Fox 2004 ➤
1. Fuel supply system components - remove and install
97
– Remove supply pipe -1- (white marking) and return pipe -2-
(blue marking) from the fuel filter.
– Connect the Vacuum pump -VAG 1390- with the Fluid con‐
tainer -VAG 1390/1- to return pipe.
– Activate Vacuum pump -VAG 1390- until no more fuel comes
from the return pipe. Take care not to suck fuel into the vaccum
pump.
– Remove vacuum hose -1- belonging to the servo brake from
auxiliary pump -4-.
– Remove supply pipe -2- (white marked) from auxiliary pump
-4-.
– Remove fastening screws -arrows-.
– Remove auxiliary pump -4- from cylinder head..
– Pull auxiliary pump -4- slightly upwards and remove return
pipe -3- (blue marking).
1.11.2
Installation
Installation is carried out by inverting the removal sequence, ob‐
serving the following:
Note
♦
Ensure proper seating of auxiliary pump coupling in camshaft.
♦
Always replace auxiliary pump seals.
– Fit return pipe -3- (blue marking) to auxiliary pump return con‐
nection.
Fox 2004 ➤
98
– Tighten lower securing bolts to 10 Nm.
– Fit supply pipe -2- (white marking) to auxiliary pump supply
connection and vacuum hose -1- from servo-assisted brake to
the auxiliary pump -4-.
– Connect pipe -1- (white marking) to fuel filter.
– Connect the Vacuum pump -VAG 1390- with the Fluid con‐
tainer -VAG 1390/1 - to return pipe.
– Activate Vacuum pump -VAG 1390- until no more fuel comes
from the return pipe. Take care not to suck fuel into the vaccum
pump.
– Fit return pipe -2- (blue marked) in the fuel filter.
1.11.3
Checking for internal leaks
Note
The tandem pump must be checked for internal leaks between
fuel side and oil side after reinstalling a used tandem pump, for
example after replacing or repairing a cylinder head and/or when
installing a "short" engine. When leaking it is possible for the fuel
to mix with the oil which may cause the engine to fail.
Special tools and workshop equipment required
♦ Tester -V.A.G 1687-
Procedure
– Pull fuel supply hose (white marking)
⇒ Item 28 (page 39)
and
fuel return hose (blue marking)
⇒ Item 29 (page 39)
off tandem
pump.
– Seal fuel return union on tandem pump with a plug. Secure
sealing plug with a spring-type clamp.
Prepare test unit -V.A.G 1687- as follows:
Fox 2004 ➤
1. Fuel supply system components - remove and install
99
– Connect test connection -5- to fuel supply union of tandem
pump using a commercially available compressed air connec‐
tion and a section of fuel hose. Use a spring-type clamp to
secure.
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air source) to
tester unit -V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure lies by 1.3 bar and this must not
be exceed.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.
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