Volkswagen FOX 2004 Workshop Manual Download Page 3

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Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 - Cylinders, engine block, support, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Removal - indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Engine - fix on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Notes regarding installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Supports for the power drive group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6

Additional removal information and instructions for vehicles with air conditioning . . . . . . . .

13 - Crankshaft, pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Crankshaft flanges and flywheel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1

Crankshaft oil seal, pulley side - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2

Crankshaft seal flange - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Counterbalance shaft and retaining frame - remove and install . . . . . . . . . . . . . . . . . . . . . . 23

3.1

Counterbalance shaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Crankshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1

Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pistons and connecting rods - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1

Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

15 - Cylinder head, valve control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1.1

Timing belt - remove and install, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2

Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.3

Compression - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Valve command - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1

Valve seats - rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.2

Valve guides - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.3

Valve stem seal - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.4

Camshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Lubrication system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.1

Crankcase - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.2

Checking the oil pressure and the oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Cooling system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.1

Cooling system components in the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.2

Cooling system components in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.3

Cooling system hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.4

Cooling system - drain and replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.5

Radiator - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.6

Water pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.7

Thermostat - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Fox 2004 ➤

3 - Cyl. diesel engine - Edition 02.2009

Contents

Summary of Contents for FOX 2004

Page 1: ...n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Fox 2004 3 Cyl diesel engine Engine ID BNM Edition 02 2009 Service Service Department Technical Information ...

Page 2: ...echnical data 10 Cylinders engine block support cover 13 Crankshaft pistons 15 Cylinder head valve control mechanism 17 Lubrication system 19 Cooling system 20 Supply system Fuel tank fuel pump 21 Overcharge turbo 23 Supply system mechanical injection diesel 26 Exhaust system 28 Chamber pre heating system Technical information should always be available to the foremen and mechanics because their c...

Page 3: ...8 2 2 Crankshaft seal flange replace 20 3 Counterbalance shaft and retaining frame remove and install 23 3 1 Counterbalance shaft remove and install 25 4 Crankshaft remove and install 29 4 1 Crankshaft dimensions 30 5 Pistons and connecting rods dismantle and assemble 32 5 1 Piston and cylinder dimensions 36 15 Cylinder head valve control mechanism 37 1 Cylinder head remove and install 37 1 1 Timi...

Page 4: ...21 Overcharge turbo 101 1 Overcharge system with turbocharger 101 1 1 Safety measures 101 1 2 Cleanliness rules 101 1 3 Turbocharger remove and install 101 1 4 Intake air cooling system intercooler components remove and install 104 23 Supply system mechanical injection diesel 106 1 Maintaining the direct injection Diesel system 106 1 1 Installation locations overview 106 1 2 Safety measures 107 1 ...

Page 5: ...max of three identification letters repre sents the the engine ID letters the second part six characters represents the serial number If more than 999 999 engines are manufactured under the same identification letters the first digit of the 6 digit group is replaced by a letter Additionally a sticker is found on the upper cover of the mechan ical distribution system arrow with the engine identific...

Page 6: ...e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 10 Cylinders engine block support cover 1 Engine remove and install Special tools and workshop equipment required Lifting tackle 2024A Engine and gearbox sup port T10012 Engine and gearbox sup port VW 313 Engine and gearbox sup port VW 540 Workshop winch V A G 1202 A Oil sump...

Page 7: ...s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Jack for Gearbox or engine gearbox combo VAG 1383A Standart type clamp pliers VAS 5024A Stepladder VAS 5085 Engine and gearbox sup port 3147 3 Washers A13 X 24 X 2 5 2 Washers A10 5 X 21 X 2 Cable tie Support bra...

Page 8: ...artment due to reduced existing space consider the following All hoses fuel hydraulics activated charcoal filter sys tem cooling fluid and gas brake fluid vacuum and elec tric cables must be restored to original positions Provide easy access to all the moving or hot parts With ignition switched off disconnect battery earth lead All cable ties that open or break during engine removal should be repl...

Page 9: ... cooling vacuum and intake system hoses from the engine Remove securing bolt of the cable support bracket and secure clutch release lever by inserting a Locking pin T10060 A arrow Remove securing bolts from the top of engine gearbox Remove cooling fluid container Unbolt starter motor and move it back until the Support 3147 can be inserted Install the Support bracket 10 222A and support engine and ...

Page 10: ...gine block Note Place two A 10 5 X 21 X 2 Washers between engine bracket and compact bracket so that the engine bracket lies flat on the com pact bracket Remove securing bolts from the bottom of engine gearbox Lift engine and gearbox lightly using the Gearbox or Engine gearbox combo jack VAG 1383A Remove the spindle of the Support bracket 10 222A on the engine side Note Use Stepladder VAS 5058 to ...

Page 11: ... VW 540 on the Stand VW 313 1 3 Notes regarding installation Installation is carried out by reversing the removal sequence considering the following Check clutch bearing for wear replace if necessary Apply a light coat of Lubricating grease G 000 100 on the clutch bearing and on the primary shaft bearing guide sleeve Check if guides for fastening engine and transmission are placed on the engine bl...

Page 12: ...5 Supports for the power drive group Tightening torque WARNING Always replace self locking nuts and screws subject to angular torque Power drive group suport engine 1 1 30 Nm 90 2 1 40 Nm 90 3 45 Nm 1 Replace 1 6 Additional removal information and in structions for vehicles with air condition ing Note The air conditioning cooling gas circuit must be opened in or der to remove the engine To prevent...

Page 13: ...m e n t C o p y r i g h t b y V o l k s w a g e n A G 13 Crankshaft pistons 1 Engine dismantle and assemble Note Where large quantities of metal shavings and filings are de tected in the engine oil during repair required as a result of crankshaft and connecting rod bearing wear the oil filter must be replaced and the oil channels carefully cleaned All bearing and running surfaces must be lubricate...

Page 14: ... Check wear Do not bend Remove install and ad just page 41 3 20 Nm 45 Replace after each remova l 4 Timing belt tension pulley 5 100 Nm 6 25 Nm 7 Camshaft gear 8 Pulley Engine speed sensor Immobilise with Coun ter hold tool T10051 to loosen or tighten To remove use Extrac tor T10052 Remove and install page 58 9 10 Nm 10 Mechanical distribution rear cover 11 Sealing ring Replace if damaged 12 Pulle...

Page 15: ...fter each removal 21 Timing belt guard centre part Part II 1 Cylinder head cover With oil filler nozzle Replace oil filling nozzle if cylinder head cover is damaged Before installation carefully clean the cylin der head sealing sur face with a clean cloth 2 To turbocharger 3 10 Nm First hand tighten all bolts Then tighten both top and remaining bolts from the inside out di agonally to specified ti...

Page 16: ...stalled Fasten with spring braces 18 Return hose To fuel filter Item 1 page 87 Blue or blue marked Check that it is securely installed Fasten with spring braces 19 Gasket Replace 20 Pin 10 Nm To engine cover 21 Engine and gearbox support 22 Hexagonal nut 23 Cylinder head gasket Replace Observe identification page 35 When replacing use completely new coolant 24 Hall Sensor G40 To the camshaft posit...

Page 17: ... Replace 5 Spacer sleeve 6 Rubber bushing 7 Engine and gearbox sup port To the Sensor Hall G40 connector of the camshaft position and Engine speed sensor G28 8 10 Nm 9 Gasket Replace 10 Oil filter bracket Disassemble and as semble page 64 11 15 Nm 90 Replace after each re moval First install upper left and lower right bolts then tighten the four bolts diagonally 12 Sealing ring Replace 13 20 Nm 14...

Page 18: ...on Rep Gr 34 23 15 Nm To remove the rear bolts close to the transmission it first must be removed Rep Gr 34 24 Cover With sealing tape Clean filter if dirty 25 Mounting frame Before installing check whether the fixing guides for centralizing on the engine block are in their place and that the fuel distribution ring is inserted in the mounting frame Remove and install page 23 26 40 Nm 27 Protective...

Page 19: ...Remove Poly V belt 1 1 2 Installation The installation is carried out by inverting the removal se quence Note Make sure before installing Poly V belt that all the ancillaries alternator air conditioning compressor are tightlysecured When fitting Poly V belt observe the direction in which it func tions and check it is seated correctly on the pulley In vehicles without air conditioning installation ...

Page 20: ... n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Belt path for vehicles with air conditioning Fox 2004 3 Cyl diesel engine Edition 02 2009 16 Rep Gr 13 Crankshaft pistons ...

Page 21: ...ditional lubricant or grease to the seal lip Before installation re move oil residues from crankshaft trunnion with a clean cloth Replace crankshaft oil seal pulley side page 18 2 Sealing flange Must be positioned on the fixing guides Remove and install page 20 Install with Silicone seal D176404 A2 page 20 3 Engine block Removing and installing crankshaft page 29 Disassemble and as semble pistons ...

Page 22: ...dditional lubricant or grease to the seal lip Before installation remove oil residues from crankshaft trunnion with a clean cloth Use protective sleeve supplied when installing First remove the protective sleeve after installing the sealing flange on the crankshaft trunnion 2 1 Crankshaft oil seal pulley side replace Special tools and workshop equipment required Extractor 3203 Lock 3415 Assembly s...

Page 23: ...he crankshaft stop Give the inside part of the Extractor 3203 two turns approx 3 mm from the external side and lock with the slotted bolt Lubricate the threaded head of the oil seal Extractor 3203 install and screw as firmly as possible onto the seal Loosen the slotted screw and turn the inner part against the crankshaft until the seal is extracted 2 1 2 Installation Note Do not apply additional l...

Page 24: ...o l k s w a g e n A G Compress the oil seal up to the stop using Press sleeve of the Assembly sleeve T10053 and the Centre bolt T10053 2 or Centre bolt T10053 3 Install and adjust timing belt page 41 2 2 Crankshaft seal flange replace Special tools and workshop equipment required Lock 3415 Assembly sleeve T10053 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 ...

Page 25: ...th the Lock 3415 Drain engine oil Remove crankcase page 68 Loosen front seal flange Remove sealing flange and release by tapping slightly with a rubber headed hammer if necessary Remove seal residues on engine block with a flat spatula Cover oil seal with a clean cloth Remove the sealant residues from the sealing flange with a rotary plastic brush use eye protection Clean the sealing surfaces They...

Page 26: ...d cannot be thicker otherwise the excess sealant could pass to the crankshaft and block the strainer of the oil suction tube as well as run along the sealing surface of the oil seal in the crankshaft Before applying the sealant cover the oil seal with a clean cloth Fasten the sealing flange immediately and lightly tighten all screws Note Use the Guide sleeve T10053 1 to fit the sealing flange with...

Page 27: ...ways replace self locking nuts and screws subject to angular torque 1 Chain Observe fastening posi tion page 25 2 100 Nm 90 Replace after each re moval The angular torque could be undertaken in several stages To loose and tighten use Multi point spanner T10061 3 Counterbalance It can be installed in one position only The holes are displaced 4 Gear For counterbalance shaft It can be installed in on...

Page 28: ...11 5 bar pressure relief valve Before installing check that both centering fastening sleeves are installed 13 Counterbalance shaft Remove and install page 25 14 Mounting frame Before installing check that the securing guides for centralizing in the engine block are in their positions and the sealing ring is inserted in the mounting frame Remove and install page 25 15 Sealing ring Replace Check tha...

Page 29: ... o p y r i g h t b y V o l k s w a g e n A G 3 1 Counterbalance shaft remove and install Special tools and workshop equipment required Pin T10060 Multi point spanner T10061 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Spanner 24 27 mm AF 3 1 1 Removal Remove Poly V belt page 14 Remove timing belt page 41 Remove crankcase page 68 Remove sealing flange pulley...

Page 30: ...ance shaft make sure that the spanner is centred on the counterbalance and at right angles to counterbalance shaft Loosen fastening bolt 2 of the counterbalance Note Only loosen the fastening bolt 2 of the counterbalance do not remove Unbolt mounting frame 3 from engine block and remove it with counterbalance shaft Put the mounting frame on a clean surface Remove counterbalance securing bolts Remo...

Page 31: ...rame with counterbalance shaft to engine block Tightening torque 20 Nm Check that mounting frame aligns flush with outer edge of en gine block on the pulley end Immobilise counterbalance shaft as shown with a Spanner 24 27 mm AF 1 Note When immobilizing the counterbalance shaft make sure that the spanner is centred on the counterbalance and at right angles to counterbalance shaft Tighten fastening...

Page 32: ...nks are marked with a notch Fit the free sprocket in the chain and tighten the free sprocket to the mounting frame Tightening torque 20 Nm Remove Locking pin T10060 from chain tensioning element Make sure that the marks on the crankshaft sprocket and counterbalance shaft sprocket align with the colour coded chain links arrows Note The colour coded chain links are marked with a notch Install pulley...

Page 33: ...aces must be lubricated before assembly WARNING Always replace self locking nuts and screws subject to angular torque 1 Bearing shells 1 2 and 4 For bearing shells with out oil groove For engine block with oil groove Do not interchange used bearing shells mark 2 65 Nm 90 Replace after each re moval To measure radial clear ance tighten to 65 Nm and no further 3 Bearing cap Bearing cap 1 Pulley side...

Page 34: ... projection out of crankshaft Special tools and workshop equipment required Depth gauge Test sequence Use Depth gauge to check projection a of fitted pin with speed sensor wheel 1 removed 1 Speed sensor rotor 2 Securing bolt 3 Projection of fitted pin 3 out of crankshaft a 2 5 3 0 mm Removing and installing speed sensor rotor Replace speed sensor rotor 2 each time the bolts 1 are loosened Tighteni...

Page 35: ...eeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Dimension for fin ishing Crankshaft trunnion Connecting rod pin Second rework 0 022 53 50 0 042 0 022 47 30 0 042 Third rework 0 022 53 25 0 042 0 022 47 05 0 042 Fox 2004 3 Cyl diesel engine Edition 02 2009...

Page 36: ...ce the apertures in 120 Remove and install us ing the piston ring pliers The mark TOP should face the piston head Check ring gap Check ring to groove clearance 2 Piston With combustion cham ber Mark installation posi tion and correspond ence with respective cylinder page 34 The arrow on the piston head should be pointed in the direction of the pulley Install by using a piston ring compressing tool...

Page 37: ...ance with Plastigage Wear limit 0 08 mm Do not rotate crankshaft while checking radial clearance 7 Engine block Check cylinder diameters page 34 Piston and cylinder dimensions page 36 8 Connecting rod cap Check installation position 9 Oil ejector For piston cooling Check assembly position Install by turning the oil ejector in counterclockwise direction up to the end 10 25 Nm Insert without sealant...

Page 38: ...B directions as illustrated Max nominal dimension deviation 0 10 mm Note The cylinder diameter cannot be measured while the engine block is secured to the assembly stand with the Engine and gearbox support VW 540 for in this case inaccurate measurements are possible Installation position and correspondence to respective cylinder Piston in cylinders 1 and 2 Larger intake valve chamber towards the f...

Page 39: ...n projection at TDC must be measured when instal ling the new pistons Depending on the piston projections install the corresponding head gasket in compliance with the table below Note Turn the engine clockwise to check the piston projections in TDC Piston projection Identification Holes grooves 0 91 mm 1 00 mm 1 1 01 mm 10 10 mm 2 1 11 mm 10 20 mm 3 Identification of cylinder head gasket Part numb...

Page 40: ...nAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 5 1 Piston and cylinder dimensions Dimension for fin ishing Piston cilinder Basic dimension mm 79 47 79 51 1 rework mm 79 97 80 01 Fox 2004 3 Cyl diesel engine Edition 02 2009 36 Rep Gr 13 ...

Page 41: ...l mechanism 1 Cylinder head remove and install Check compression page 49 Note When mounting a replacement head with the camshaft moun ted lubricate all the contact surfaces between tappets and cams before installing the head cover All bearing and running surfaces must be lubricated before assembly The plastic shims provided for protecting the open valves should not be removed until immediately bef...

Page 42: ...en To remove use the Pull er T10052 Remove and install page 58 8 Mechanical distribution rear cover 9 Sealing ring Replace if damaged 10 Hall Sensor G40 To the camshaft posi tion To remove remove sealing ring 11 Cylinder head securing bolt Replace Check the sequence when loosening or tightening page 46 Before installing set washers in cylinder head 12 Pin 10 Nm To engine cover 13 Cylinder head cov...

Page 43: ...2 20 Nm 23 Lifting eye 24 Injection unit Remove and install page 112 25 Central connector To injector 26 From servo brake 27 Tandem pump For supplying fuel and vacuum Remove and install page 97 Check page 95 28 Supply hose From fuel filter Item 1 page 87 White or with white marking Check that it is securely installed Fasten with spring braces 29 Return hose To fuel filter Item 1 page 87 Blue or bl...

Page 44: ... V o l k s w a g e n A G 36 Tensioning element 37 20 Nm 45 Replace after each removal Check the cylinder head for bending Max permissible bending 0 1 mm Note Diesel engine head rework is not permitted Identification of cylinder head gasket Part number arrow 1 Production control code arrow 2 can be disregarded Holes arrow 3 Note Different cylinder head gasket thicknesses are mounted depend ing on t...

Page 45: ... r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 1 Timing belt remove and install adjust Special tools and workshop equipment required Diesel injection pump lock ing pin 3359 Pin wrench 3387 Crankshaft stop T10050 Fitter T10015 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Support bracket ...

Page 46: ...pending on the engine temperature Remove the engine cover Remove the hose between intercooler and intake connecting flange Fit Support bracket 10 222 A as shown and support the en gine in its installation position Remove engine support 1 and engine console 2 Remove Poly V belt page 14 Remove Locking pin T10060 from tensioning element Remove mechanical distribution upper cover Remove lower noise in...

Page 47: ...To do this push crankshaft stop from the face side of the gear into the gear teeth Note The marks on the crankshaft gear and the crankshaft stop must align At the same time the shaft of the crankshaft stop must en gage into the hole in the sealing flange Mark timing belt operation direction Loosen securing nut of the tensioning element Loosen the fastening bolts of the camshaft gear 1 until the ge...

Page 48: ...Pin wrench 3387 in the direction of arrow until the indicator is in the middle of the gap in the base plate arrow Secure the tensioning element in this position and tighten the fastening nut with 20 Nm 45 Tighten fastening screws of the camshaft gear to 25 Nm Remove Mandrel 3359 and Crankshaft stop T10050 Turn crankshaft twice in the engine rotation direction until it is again in the TDC of cylind...

Page 49: ...Crankshaft stop T10050 Turn crankshaft twice in the engine turn direction until it is in the TDC of cylinder 1 again Note When doing this the crankshaft stop end shall engage in the sealing flange while turning the engine When the crankshaft is turned beyond the TDC of cylinder 1 and the crankshaft stop is not engaged in the sealing flange turn the crankshaft 1 4turn in the reverse direction in or...

Page 50: ... c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Cylinder head remove and install Special tools and workshop equipment required Support 10 222A Support T10014 Tray VAG 1306 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Vacuum pump V A G 1390 Fluid receptacle V A G 1390 1 1 2 1 Removal Remove...

Page 51: ...ened to the engine block for removing the cylinder head Fit Support bracket 10 222A as shown and support the en gine in its installation position Carefully lift the engine slightly with spindle A Attach Retainer T10014 to engine block using the threaded hole in the vicinity of water pump as illustrated Tightening torque 20 Nm Lift engine slightly using second spindle B until spindle A is relieved ...

Page 52: ...emely carefully Damage to the silicone layer or the indented area will cause leakage Turn the crankcase to the TDC marking before installing the cylinder head Turn crankshaft in the opposite direction of engine rotation until all the pistons are approximately equally placed below TDC Place head gasket Fit cylinder head and hand tighten all its bolts Tighten the cylinder head in four stages as foll...

Page 53: ... m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 3 Compression check Special tools and workshop equipment required U J extension and socket 10 mm 3220 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Adapter V A G 1381 12 Compression meter V A G 1763 Test conditions Minimum engine oil temperature 30 C Test sequence Remove central connector from unit injectors Remov...

Page 54: ... with the Compression meter V A G 1763 Note How to use the compression meter Instruction Manual Operate the starter motor until the meter does not indicate fur ther increase in pressure Compression pressure New 25 31 bar Wear limit 19 bar Permissible difference between all cylinders 5 bar Install glow plugs with U J extension and socket 10 mm 3220 Tightening torque 15 Nm Check fault memory elimina...

Page 55: ...st be lubricated before in stalling WARNING Always replace self locking nuts and screws subject to angular torque 1 20 Nm 90 Replace after each re moval Loosen and tighten in the proper order page 58 2 Injector drive arm shaft 3 Cylinder head securing bolt Replace Loosen and tighten in the proper order page 46 Before installing set washers in cylinder head 4 Washer For head screws 5 Tappet Do not ...

Page 56: ...l Do not apply additional lubricant or grease to the seal lip Before installation remove oil residues from crankshaft trunnion with clean cloth For installation cover the groove in the camshaft tapered section with adhesive tape Remove and install 15 Valves Valve dimensions page 53 16 Bearing shell Do not interchange used bearing shells mark Ensure proper seating of retaining clips in bearing caps...

Page 57: ...ly Sealant AMV 17400401 thin and evenly on surfaces 1 Note Ensure that no sealant enters grooves arrows Bearing cap 4 is identified as bearing cap 5 Valve dimensions Note Valves cannot be reworked Only lapping in is permitted Dimension Intake valve Escape valve a mm 35 95 31 45 b mm 6 980 6 956 c mm 89 95 89 95 α 45 45 Valve identification and synchronization Identification Cam base diameter a 52 ...

Page 58: ...e tasks When the rework measurement is exceeded the hydraulic compensation function of the tappets will not be guaranteed and the engine head must be replaced 2 1 1 Calculating the maximum reworking di mension allowed Install valve and firmly press it against seat Note In case the valve is replaced during repairs use new valve for measurement Measure the distance a between valve stem end and engin...

Page 59: ...b y V o l k s w a g e n A G 2 1 3 Reworking escape valve seat a 31 4 mm b 2 7 mm 45 Valve seat angle 2 2 Valve guides check Special tools and workshop equipment required Support VW 387 Dial gauge Test sequence Place a new valve on the guide Valve stem end shall be aligned with guide Due to differences in valve stem diameters fit intake valves in the intake guides and exhaust valves in ex haust gui...

Page 60: ...d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 3 Valve stem seal replace Special tools and workshop equipment required Device 2036 Extractor 3047A Fitter 3129 Lever VW 541 1A Supporting part VW 541 5 2 3 1 Removal with engine head installed Remove camshaft page 58 Remove tappets and place them with contact surface turned downwards When doing this ensure that the tappets are not in...

Page 61: ... g h t b y V o l k s w a g e n A G Fit the Device 2036 and adjust to height of plates Remove valve springs with Lever VW 541 1A and Support ing piece VW 541 5 Note Valves then will lean against piston head Pull off valve stem seals with Puller 3047 A 2 3 2 Installing Install the plastic sleeve A supplied in the respective valve stem This will prevent the new valve stem B from being damaged Insert ...

Page 62: ...r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 4 Camshaft remove and install Special tools and workshop equipment required Blocking device T10051 Extractor T10052 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Torque wrench 40 to 200 Nm enc 1 2 VAG 1332 Seal AMV 17400401 2 4 1 Removal Remove Poly V belt page 14 Remove timing belt page 41 Remove fastening screw...

Page 63: ...amshaft Note Hold puller with a spanner while doing the above operation Remove the camshaft hub Remove cylinder head cover Remove injector drive arm shaft Note First loosen the outer securing bolts then one bolt of each pair of inner securing bolts and lastly the other bolt of each pair Remove auxiliary pump page 97 First remove bearing caps 2 and 3 Then loosen bearing caps 1 and 4 alternately and...

Page 64: ...xiliary pump Install the camshaft seal Fit injector drive arm shaft and tighten first one bolt of each of the inner pairs then the other bolt of each pair and finally the outer securing bolts evenly and alternately until there is no more play in bearing and finally tighten to torque Tightening torque 20 Nm 90 replace Install the hube on camshaft Tighten hub fastening screw 1 Tightening torque 100 ...

Page 65: ...engine oil during engine repair due to crankshaft and rod bearing wear the oil filter must be replaced and the oil gallery must be carefully cleaned The oil level should not exceed the maximum marking risk of damage to the catalytic converter All bearing and running surfaces must be lubricated before assembly WARNING Always replace self locking nuts and screws subject to angular torque Check oil p...

Page 66: ...age 17 Do not apply additional lubricant or grease to the seal lip Before installation re move oil residues from crankshaft trunnion with a clean cloth Replace cranckshaft oil sealing pulley end page 17 3 Engine block 4 Gasket Replace 5 Oil filter bracket Disassemble and as semble page 64 6 15 Nm 90 Replace after each re moval First fit upper left and lower right bolts then tighten the four bolts ...

Page 67: ...llation position Install by turning the oil ejector counterclockwise up to the stop 20 Sealing ring Replace 21 Crankcase Clean sealing surface before installation Install with Silicone sealant D 176 404 A2 page 68 To remove crankcase firstly remove the transmission Rep Gr 34 22 Support For intercooler hose 23 15 Nm To remove the rear bolts near the transmission the latter must be removed Rep Gr 34...

Page 68: ...with Locking pin T10060 Remove and install page 23 36 Sealing ring Not applicable 37 Oil level and temperature sensor G266 Not applicable Part II WARNING Always replace self locking nuts and screws subject to angular torque 1 Packing Replace 2 15 Nm 90 Replace after each re moval First fit upper left and lower right bolts then tighten the four bolts di agonally 3 Oil filter bracket 4 Packing Repla...

Page 69: ... n A G 10 Oil filter element 11 Sealing plug 10 Nm 12 Gasket Replace Install in the oil radiator groove 13 Oil radiator Check installation position See note page 61 14 Gasket Replace 15 Sealing plug 25 Nm Part III 1 Safety nut 22 Nm When loosening and tightening hold the con nection 2 Connection Remove and install Item 5 page 64 3 Packing Replace 4 Oil filter bracket 5 Oil supply tube To the turbo...

Page 70: ...A G Marks on the oil dipstick 1 max mark 2 min marks a Region between the upper corner of the hachured region and the max mark do not replenish with oil b Oil level in the hachured field May be filled with oil c Region between min mark and lower corner of hachured area Replenish at most 0 5 l of engine oil Assembly sequence Removal Remove noise insulation Place Drainage tank V A G 1306 underneath ...

Page 71: ...w a g e n A G Remove safety nut 1 on turbocharger 12 locking the con nection 11 Remove bolt 10 from bracket 8 Remove nut 7 and take off bracket 8 Remove oil supply tube 5 Installing Install in the reverse sequence observing the following WARNING Oil supply line assembly shall be carried out as described be low Screw bracket 8 with nut 7 loosely to exhaust manifold Manually tighten the safety nut 1...

Page 72: ...lt 10 Tighten nut 7 1 1 Crankcase remove and install Special tools and workshop equipment required Portable drill with plastic brush Silicone sealant D176404 A2 Flat spatula 1 1 1 Removal Remove lower noise insulation from engine Rep Gr 50 Drain engine oil Remove gearbox Rep Gr 34 Remove crankcase If necessary loosen crankcase by tapping slightly with rubber hammer Eliminate sealing residues that ...

Page 73: ... silicone sealant as shown onto crankcase clean seal ing surface Sealing cord shall Be 2 3 mm thick Run on inside of bolt holes region arrows Note Sealing cord may not be thicker otherwise excess sealant may drop into crankcase and block suction tube strainer Install crankcase immediately and slightly tighten all the bolts Note Crankcase shall be aligned with engine block Tighten bolts to 15 Nm In...

Page 74: ... s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Checking the oil pressure and the oil pressure switch Special tools and workshop equipment required Oil pressure meter V A G 1342 Test probe VAG 1527B Auxiliary measuring cable set VAG 1594C Note Operation and maintenance test of visual and acoustic oil pres sure indicator Current flow diagra...

Page 75: ...test equipment Install test equipment in place of the oil pressure switch on the oil filter support Connect brown wire of tester to earth Connect Test probe VAG 1527B using Aux measuring ca ble set VAG 1594C to battery positive terminal and Oil pressure switch F1 Start engine and increase speed slowly In 0 55 0 85 bar the LED shall light OFF otherwise replace the Oil pressure switch Continue incre...

Page 76: ...em is under pressure when the engine is hot Thus it is necessary to reduce the pressure before doing re pairs Hose junctions are fastened by spring clamps When doing repairs use spring clamps only To install spring clamps we recommend using Standart type clamp pliers VAS 5024A or Hose clip pliers VAG 1921 Check the cooling system tightness with the Engine cooling sys tem tester VAG 1274 and the Ad...

Page 77: ...ling system hose Hose connection dia gram page 75 4 Cover Check with Engine cool ing system tester VAG 1274 and the Adapter for VAG 1274 VAG 1274 9 Test pressure 1 4 1 6 bar 5 Connector 6 5 Nm 7 Coolant reservoir Check cooling system tight ness with the Engine cooling system tester VAG 1274 and the Adapter for VAG 1274 VAG 1274 8 8 Air ducts 9 5 Nm 10 Fan ring 11 10 Nm 12 Radiator fan 13 Support F...

Page 78: ...5 Nm 6 Hose To the lower side of the coolant reservoir Hose connection dia gram page 75 7 Fastening support 8 Cooling system pipe Hose connection dia gram page 75 9 Sealing ring Replace 10 Hose To upper side of the ex pansion reservoir Hose connection dia gram page 75 11 Hose To upper side of radia tor Hose connection dia gram page 75 12 Hose From lower side of radiator Hose connection diagram pag...

Page 79: ...u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove and install page 80 17 Sealing ring Check it is securely seated Replace 18 Clip Check it is securely seated 19 Coolant temperature sensor G62 With the Coolant temperature sensor G2 1 3 Cooling system hose connection diagram 1 Coolant reservoir 2 Intake manifold 3 Engine block cylinder head 4 Heating system heat ex changer 5 Radiator Fo...

Page 80: ... n t C o p y r i g h t b y V o l k s w a g e n A G 1 4 Cooling system drain and replenish Special tools and workshop equipment required Refractometer for cooling system fluid analysis T10007 Tray V A G 1306 Standart type clamp pliers VAS 5024A No illustration Cooling system supply unit VAS 6096 1 4 1 Drain Remove coolant reservoir cover WARNING Steam may be released when the coolant reservoir cove...

Page 81: ...eeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Remove plug arrow for draining the cooling system Also disconnect the oil radiator hose arrows Note Follow the recommendations for coolant disposal Fox 2004 3 Cyl diesel engine Edition 02 2009 1 Cooling syst...

Page 82: ...ust be ensured to approximately 25 C in arctic climate countries to approximately 35 C The coolant concentration must not be reduced by adding wa ter during hot seasons or in countries with hot climates The antifreeze proportion shall be at least 40 If because of climatic conditions greater antifreeze protection is necessary the percentage of Additive G12 may be in creased however only upto the li...

Page 83: ...eservoir cover Turn off heating start device Start engine and maintain an speed of about 2000 rpm for ap prox 3 minutes Run engine until the radiator fan starts Check coolant level and if necessary replenish With engine hot the coolant level shall be on max marking with engine cold it must be between the max and min marks 1 5 Radiator remove and install Special tools and workshop equipment require...

Page 84: ...emove radiator securing bolts and remove radiator with fan from downwards Vehicles with air conditioning system For removal refer to the additional information and instruc tions page 8 1 5 2 Installing Installation is carried out by inverting the removal sequence ob serving the following Fill cooling system page 76 Vehicles with air conditioning system For removal refer to the additional informati...

Page 85: ...oval 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 tor...

Page 86: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 7 Thermostat remove and install 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 Remove ...

Page 87: ...ction flange 2 and remove connection flange 2 with thermostat 4 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 thermost...

Page 88: ...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 ins...

Page 89: ...securely connected 14 Bearing 15 Expansion tank 16 Fuel pump Check the flange installation position in the fuel tank page 86 Remove and install page 91 Check fuel pump page 92 With fuel gauge sensor G Remove and install fuel meter sensor page 92 Clean strainer if soiled 17 Sealing ring Replace if damaged Moisten with fuel when installing the pump 18 Circlip Remove and install with Spanner VW 5321 ...

Page 90: ...avity valve 3 Expansion tank 4 Vent hose From the fuel tank 5 Anti choke hose From the fuel tank Fuel pump installation position 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 f...

Page 91: ... it is securely connected 3 Control valve Assembly position the arrow must point to fuel tank When replacing the fil ter remove the fasten ing clip and completely remove the control valve along with the fuel pipes Below 15 C Passage to filter open Over 31 C Passage to filter closed 4 Supply tube To auxiliary pump Check that it is securely connected White or with white marking 5 Return pipe From au...

Page 92: ...r when carrying out any repairs to the fuel system Before starting installation work place a gas exhaust hose of a switched on gas exhaust system near the fuel tank opening so as to absorb gases released by the fuel If exhaust equi ment is unavailable use a radial fan the motor must be out of air flow with air movement rate higher than 15 m3 hour Avoid skin contact with fuel Use fuel resistant glo...

Page 93: ...t C o p y r i g h t b y V o l k s w a g e n A G Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Jack Gearbox or engine gearbox VAG 1383A 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 di...

Page 94: ...flector 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 ...

Page 95: ...panner 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...

Page 96: ...ote 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 tan...

Page 97: ...voltage Fold rear seat forwards Remove fuel pump access cover Briefly operate starting motor The fuel pump operation must be audible Switch off ignition If fuel pump does not work Remove 4 pin connector from the fuel pump flange Connect Test probe VAG 1527B to outer contacts of con nector using adapter cables from V A G 1594 Switch ignition on The LED shall light ON for about 2 seconds If the LED ...

Page 98: ...Multimeter V A G 1715 test probe can also be inserted be tween the contact 1 connector and the fuel pump by using the adapter cables of the Multimeter V A G 1715 Connect contacts 4 of connector and fuel pump by using the adapter cables from V A G 1594 A Start engine and run at idle speed Measure current at fuel pump Specification 6 3 7 8 A If the values measured lie outside the specifications Repl...

Page 99: ...i g h t b y V o l k s w a g e n A G 1 10 Auxiliary pump check Special tools and workshop equipment required Pressure test equipment VAS 5187 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 Vehicle diagnosis measurement and information system VAS 5051A 52 with Diagnostic cable 3 m VAS 5051 5 Test conditions Coolant temperature at least 85 C Injectors must be in order Fuel filter and pipes must not be blo...

Page 100: ...surement and Information Sys tem VAS 5051A 52 and select the operation mode Vehicle self diagnosis Then select engine electronic control unit with 01 Engine electronic system Select function 08 Read value block Select screen 2 via numeric keys on keyboard and confirm with Q key Read engine idle speed on field 1 Increase engine speed to 1 500 rpm Check pressure on the pressure gauge Specification a...

Page 101: ...t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 11 Auxiliary pump remove and install 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 3 Cyl diesel engine...

Page 102: ...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 re...

Page 103: ...G 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 ...

Page 104: ...on 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 a...

Page 105: ...easuring equipment on the back seat to be operated by someone from there If test and measuring equipment are operated from the passenger seat the person seated there may be injured should the airbag activate in case of accident 1 2 Cleanliness rules When working on the overcharge system pay careful attention to the following cleanliness rules Carefully clean all the connections and surrounding are...

Page 106: ...s containing lubricant on its connections Overcharge system must be free of leaks Before installing the oil supply pipe fill the turbocharger through the connection point with engine oil After installing the turbocharger run the engine during at idle speed for about 1 minute Do not accelerate the engine This will ensure the turbocharger is properly lubricated Always replace self locking nuts Hoses...

Page 107: ...st gas recirculation valve and the intake manifold valve motor as well as the drive shaft right cov er 2 Intake manifold 3 From the intercooler 4 Gasket Replace Covering fillet towards the intake manifold 5 25 Nm 6 Gasket Check installation posi tion 7 From the air filter 8 Support From heat deflector 9 Washer 10 25 Nm 11 Heat deflector Fasten on the bracket 12 Hollow screw 15 Nm 13 Packing Replac...

Page 108: ... G 21 Oil supply tube From oil filter support Before installing check oil supply tube for continuity Before installing fill turbocharger with engine oil through the oil supply tube connection Remove and install page 65 22 10 Nm 23 Support 1 4 Intake air cooling system intercooler components remove and install Note All the hoses are fastened by clamps When required use sliding agent water without a...

Page 109: ... o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 Air ducts 2 Intercooler 3 8 Nm 4 Sealing ring Replace if damaged 5 Intake manifold pressure sensor G71 with Intake mani fold temperature sensor G72 6 Support 7 5 Nm 8 Hose 9 Tube 10 From exhaust gas recircu lation valve 11 From the air filter 12 From head cover 13 Tube 14 Exhaust manifold 15 Tube...

Page 110: ...ge 107 1 1 Installation locations overview Components A to D are not shown in the illustration A Brake pedal switch F47 or Brake light switch F Together in one case in the feet compartment on the brake pedal B Accelerator pedal position sensor G79 and Sensor 2 of accelerator pedal position G185 At the feet compart ment on the accelerator pedal C Clutch pedal switch F36 In feet compartment on clutc...

Page 111: ...to their original positions Provide easy access to all moving or hot parts If during a test drive it is necessary to use test and measuring equipment observe the following Always install test and measuring equipment on the back seat to be operated by someone from there If test and measuring equipment are operated from the passenger seat the person seated there may be injured should the airbag acti...

Page 112: ...efully preserved Install only clean components Only remove spare parts from packaging just prior to installing them Do not install compo nents that have been kept out of packaging i e inside the tool box etc With system open If possible avoid using compressed air If possible do not move the vehicle Also ensure that no diesel runs onto the cooling system ho ses Hoses coming in contact with fuel mus...

Page 113: ... sealing rings WARNING Always replace self locking nuts and screws subject to angular torque 1 20 Nm 90 Replace after each re moval 2 Rocker arm shaft With rocker arm Remove and install page 112 3 Self locking nut 4 Set screw Replace 5 Ball head pin Replace 6 Injectors Remove and install page 112 7 Sealing ring Replace page 109 8 Sealing ring Replace page 109 9 Sealing ring Replace page 109 10 Hea...

Page 114: ...Installation Note Always use the assembly sleeves to fit the rings If the as sembly sleeves are not used the rings may be damaged Gradually introduce the rings with no coloured markings Then check that the rings are correctly positioned in their respective grooves Ring size decreases towards nozzle Prevent the rings from rolling when sliding them on The rings must not be twisted when seated on the...

Page 115: ...t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Slide Assembly sleeve T10056 2 to stop position on unit in jector Slide intermediate ring carefully towards assembly sleeve and into injector seat Remove assembly sleeve Slide Assembly sleeve T10056 3 to stop position on unit in jector Slide lower ring carefully towards assembly sleeve and into injector seat Remove assembly slee...

Page 116: ...10054 Extractor T10055 Torque wrench 5 to 50 Nm enc 1 2 VAG 1331 1 7 1 Removal Remove the upper cover of the mechanical distribution and the cylinder head cover Turn crankshaft until the cams of the injector to be removed point upwards Loosen self locking nuts of set screws 1 and remove the screws Remove rocker arm securing bolts 2 from outwards to in wards with Multi tooth socket 3410 and remove ...

Page 117: ...with rings and heat insulation cover The heat insulation cover and rings must be replaced when the old injector is reused page 109 Check whether the three rings and the heat insulation cover together with the fastening clip are correctly seated before installing the injector Note The rings cannot not be twisted Lubricate the rings and carefully set the injector into the cylin der head In a uniform...

Page 118: ...12 Nm 270 the angular torque could be made in several stages Fit the rocker arm shaft and tighten the new securing bolts as follows Tighten the inner and then both outer bolts manually and evenly Next by using the same sequence tighten to 20 Nm 90 Fit the Bracket VW 387 onto the set screw as shown Turn crankshaft in the engine rotation direction until rocker arm roller is at the top of drive cam R...

Page 119: ... to the command unit ID and this respective code page 115 2 1 1 Removal Switch off ignition Remove the windscreen wiper blades and the lower coating of the windscreen frame Release the connector on the engine command unit and pull it off Push clips arrows outwards and pull command unit out 2 1 2 Installing Insert new command unit Fit connector and lock in position Check the previous code and encod...

Page 120: ...ress on the 01 Engine electronic system The command unit ID and the code will be indicated on the dis play Select diagnosis function Press on the 02 Query fault memory on the display If no faults are stored in engine command unit the display shows 0 faults found If there are faults stored in the engine command unit they will appear sequentially on the display Press key Press on the 05 Erase fault ...

Page 121: ...genAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Select 01 systems with self diagnosis Select engine control Select functions Select function or component Fox 2004 3 Cyl diesel engine Edition 02 2009 2 Engine command unit 1...

Page 122: ...w a g e n A G 26 Exhaust system 1 Exhaust system components re move and install Note Removing and installing exhaust manifold page 101 After repairing the exhaust system check that there is no volt age and the clearance with the body is sufficient When re quired loosen double clamp or clamps and align silencer and exhaust tube so that sufficient body clearance is maintained and the weight is evenl...

Page 123: ... s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 Gasket Replace 2 Self locking nut 25 Nm Replace after each re moval 3 Support strap Replace if damaged 4 Front exhaust pipe with cat alytic converter 5 Marking 6 Dimension a 5 mm 7 Double clamp 8 Self locking nut 40 Nm Replace after each re moval 9 Support With support strap Replace if damage...

Page 124: ...culation EGR valve N18 The tapered plunger of the Exhaust gas recirculation valve N18 enables the cross section variation in function of the different plunger positions The control by pulses makes feasible all the valve opening positions Always replace self locking nuts 2 1 Exhaust gas recirculation system components remove and install 1 Intake manifold 2 Sealing ring Replace 3 Intake connection f...

Page 125: ... o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 2 Vacuum hose connection diagram Solenoid valve connections 1 Turbocharger air filter hose 2 Turbocharger vacuum unit 3 Overcharge pressure connection in the turbocharger 4 BNM engine code sealed 5 Air filter 6 Vacuum connection in the non return valve to servo brake 7 Exhaust...

Page 126: ... V o l k s w a g e n A G 28 Chamber pre heating system 1 Chamber pre heating system check Special tools and workshop equipment required Portable multimeter VAG 1526C Auxiliary measuring cable set VAG 1594C Test conditions Battery voltage at least 11 5 V Ignition switched off Direct injection diesel system command unit J248 OK Fuse 4 30 in the fuse holder S176 Fuse 5 30 in the fuse holder S177 and ...

Page 127: ...he ignition on the combustion cham ber pre heating period will occur Remove heating plug connectors Connect the multimeter to measure voltage between the heat ing plug connector and vehicle earth Start the ignition during approx 20 seconds The battery volt age shall appear on the panel If no voltage is indicated Vehicle diagnosis testing and in formation system VAS 5051 1 1 Checking heating plugs ...

Page 128: ...i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Connect the Test probe VAG 1527B wire using the Meas urement auxiliary cable set VAG 1594C to the battery positive terminal Position the Test probe VAG 1527B on each heating plug one by one Diode lights up heating plug OK If diode does not light up replace heating plug Remove and install heating plugs w...

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Volkswagen FOX 2004, Workshop Manual

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