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Workshop Manual
Fox 2004 ➤
3 - Cyl. diesel engine
Engine ID
BNM
Edition 02.2009
Service
Service Department. Technical Information
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical 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
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R007720
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Cylinders, engine block, support, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Engine - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removal - indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Engine - fix on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes regarding installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Supports for the power drive group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Additional removal information and instructions for vehicles with air conditioning . . . . . . . . 8
13 - Crankshaft, pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Engine - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Crankshaft flanges and flywheel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Crankshaft oil seal, pulley side - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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 Timing belt - remove and install, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Compression - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 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
1 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
1 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 i
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20 - Supply system - Fuel tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Fuel supply system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Fuel tank components with accessories - remove and install . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Fuel filter - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.3 Safety measures for working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Fuel tank - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.6 Fuel pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Fuel meter sensor - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.8 Fuel pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.9 Accelerator mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.10 Auxiliary pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.11 Auxiliary pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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
1.3 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.4 Intake manifold valve - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Injectors - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Sealing ring for injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.7 Injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Engine command unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Engine command unit - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Querying and erasing fault memory of the engine command unit . . . . . . . . . . . . . . . . . . . . 115
2.3 Adjusting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1 Exhaust system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Exhaust gas recirculation system components - remove and install . . . . . . . . . . . . . . . . . . 120
2.2 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
28 - Chamber pre-heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1 Chamber pre-heating system - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Checking heating plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
ii Contents
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00 – Technical data
1 Technical data
1.1 Engine number
Engine number (“identification letters” and “serial number”) is en‐
graved on the flange between the engine and the transmission.
The engine number comprises a maximum nine digits (alphanu‐
merical). The first part (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 identification
letters” and the “serial number”.
The “engine identification letters” are also indicated on the vehicle
data plate.
1.2 Engine features
Engine codes BNM
Production 11.04 ▸
Cylinder volume l 1,4
Power kW / rpm 51/4000
Torque Nm / rpm 155/1600 to 2800
Bore ∅Ø mm 79,5
Stroke mm 95,5
Compression rate 19,5
Octanage at least 49
Firing order
1-2-3
Catalytic converter yes
Recirculation of exhaust gases yes
Charged yes
Intercooler yes
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Technical data 1
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.
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 -V.A.G 1306-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2 Rep. Gr.10 - Cylinders, engine block, support, cover
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♦ 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 bracket -10-222A- with Rack -10-222A/1-
♦ Adapter -10-222A/18-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 3
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.
Modifying Engine bracket -T10012-
– If the modification has not yet been carried out, drill an addi‐
tional hole -a- to the prescribed dimensions at the same height
as the other holes.
1.1 Removal - indications
Note
Check whether vehicle has code radio, if so obtain the anti-theft
code before disconnecting earth lead from battery.
– The engine is removed downwards, along with transmission.
WARNING
For installation jobs, especially in the engine compartment, 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 replaced and installed at the same locations when engine
is installed.
– Release the supply and return hoses in the cylinder head.
WARNING
♦ The fuel and the fuel system hoses may be very hot (burn
risk)!
♦ Fuel system is under pressure!
♦ Use protective gloves and goggles when performing any
repairs on the fuel system!
– Remove connecting pipe between intercooler and intake con‐
necting flange.
– Remove air mass meter hose from turbocharger.
– Remove lower noise insulation from engine ⇒ Rep. Gr. 50
– Remove intercooler/turbocharger hose.
– Remove Poly-V belt ⇒ page 14 .
– Drain the cooling system ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
4 Rep. Gr.10 - Cylinders, engine block, support, cover
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– Release the radiator cooling system hoses from the engine by
using Hose clamp pliers -V.A.G 1921- or Standart-type clamp
pliers -VAS 5024A- .
– Remove/disconnect all the electric connections from the en‐
gine where necessary.
– Remove all the 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
gearbox as shown in diagram.
– Remove engine support -1- and engine console -2-.
– Disconnect right-hand drive shaft⇒ Rep. Gr. 40 .
– Loosen front exhaust pipe from turbocharger. Loosen double
clamp and push exhaust pipe backwards ⇒ page 118 .
– Remove the protection plate behind the drive shaft flange.
Vehicles with air conditioning:
– For removal, refer to the additional information and instruc‐
tions ⇒ page 8 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 5
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– Install support pin to the engine bracket-1- with one washer
and the pin -2- with two A13 X 24 X 2.5 washers as shown in
the illustration -arrows-.
– Then, secure the Engine bracket -T10012- with nut -3- and
securing bolt from the compact bracket on the engine 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 remove the spindle.
– Separate engine from gearbox by carefully lowering it and us‐
ing the Gearbox or Engine + gearbox combo jack -VAG
1383A;- remove it from below.
Note
When lowering, handle the engine carefully to prevent damaging
the body.
1.2 Engine - fix on assembly stand
To perform the assembly work, the Engine and gearbox support
-VW 540- must be fastened on the assembly stand -VW 313- .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
6 Rep. Gr.10 - Cylinders, engine block, support, cover
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Work sequence
– Attach with Lifting tackle -2024A- as follows and lift a little with
the Engine/gearbox combo jack -VAG 1383A- .
Pulley side: 4th hole of the bar in position 1.
Engine flywheel side: 2nd hole of the bar in position 8.
WARNING
On hooks and pins, use safety locks -arrows-.
Note
♦
Positions numbered 1...4 on suspension bar face toward the
pulley.
♦
Drilled holes on supports are counted from the hook.
– Fasten the engine with the Support -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 block and, if necessary, install them.
– Align engine, moving it slightly so that the supports are seated
without stress.
Note
Assembly support tightening torques ⇒ page 8 .
– Electrical conections and installation ⇒ Rep. Gr. 97 :
– Remove Locking pin -T10060- -arrow- and replace securing
bolt.
– Install drive shaft ⇒ Rep. Gr. 40 .
– Install the front exhaust pipe ⇒ page 118 .
– Install Poly-V belt ⇒ page 14 .
– Install air filter/turbocharger, intercooler/turbocharger and in‐
tercooler/intake flange hoses.
– Fill cooling system ⇒ page 76 .
– Install engine noise insulation ⇒ Rep. Gr. 50 .
– Perform test drive and check fault memory ⇒ page 115 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 7
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1.4 Tightening torque
Location
Tightening tor‐
que
Screws, nuts M 6 10 Nm
M 8 20 Nm
M 10 45 Nm
M 12 60 Nm
Different tightening torques
Front exhaust and turbocharger pipe 25 Nm
1.5 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 damages to condenser and cooling gas hoses, do
not fold, twist or overstretch the hoses.
– Remove air conditioning compressor and anchor it to the body.
⇒ Rep. Gr. 87 .
– Purge the cooling gas from air conditioning circuit and open
the gas circuit ⇒ Rep. Gr. 87 .
Note
The air conditioning compressor may remain fitted in its place.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
8 Rep. Gr.10 - Cylinders, engine block, support, cover
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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 lubricated before
assembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 9
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I ⇒ page 10
II ⇒ page 11
III ⇒ page 12
Part I
1 - Timing belt guard - upper
part
2 - Timing belt
❑ Mark rotation direction
before removal.
❑ 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 - Pulley
13 - Water pump
❑ Remove and install ⇒ page 80 .
14 - Crankshaft gear
15 - 120 Nm + 90°
❑ Replace after each removal..
❑ Immobilise with Lock -3415- to loosen or tighten.
❑ Do not apply additional oil or grease to the threads and recess/flanges.
❑ The angular torque can be performed in several stages.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
10 Rep. Gr.13 - Crankshaft, pistons
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16 - 15 Nm
17 - 20 Nm
18 - Lower part of mechanical distribution cover
19 - Vibration cushioning pulley
❑ It can be installed in one position only. The holes are displaced.
20 - 10 Nm + 90°
❑ Replace after 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
tightening torque.
4 - Pressure regulating valve
❑ To crankcase vent.
5 - Cover
❑ Replace seal if dam‐
aged.
6 - Gasket
❑ Replace if damaged.
7 - Oil filling nozzle
❑ Replace.
8 - Engine and gearbox sup‐
port
❑ With fuel tube.
9 - Cylinder head cover gasket
❑ Replace if damaged.
10 - 20 Nm
11 - Lifting eye
12 - 10 Nm
13 - Central connector
❑ To injector
14 - From servo brake
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 11
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15 - Tandem pump
❑ For supplying fuel and vacuum.
❑ Remove and install ⇒ page 97 .
❑ Check ⇒ page 95 .
16 - 25 Nm
17 - Supply hose
❑ From fuel filter ⇒ Item 1 (page 87) .
❑ White or with white marking.
❑ Check that it is securely installed.
❑ 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 position.
❑ Loosen to remove sealing ring from the mechanical distribution rear cover.
25 - Cylinder head securing bolt
❑ Replace.
❑ Follow the installation and removal sequence ⇒ page 46 .
❑ Insert washers into cylinder head before installing.
26 - Injectors
❑ Remove and install ⇒ page 112 .
Part III
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
12 Rep. Gr.13 - Crankshaft, pistons
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1 - 45 Nm
2 - Engine bracket
3 - Engine block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 17 .
❑ Disassemble and as‐
semble pistons and con‐
necting rods
⇒ page 32
4 - Connection, 40 Nm
❑ To turbocharger oil re‐
turn pipe .
❑ 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 - Engine speed sensor -G28-
15 - Connection
❑ To temperature sensor.
16 - 15 Nm
17 - Coolant temperature sensor
❑ Remove and install ⇒ page 82 .
18 - 45 Nm
❑ Torque sequence: from inside out.
19 - Compact bracket
❑ To alternator, air conditioning compressor and Poly-V belt tensioning element.
❑ See the locating guide between compact bracket and engine block.
20 - Tensioning element
❑ To Poly-V belt.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 13
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21 - 25 Nm
22 - Oil crankcase
❑ Clean sealing surface before installation.
❑ Install with Silicone sealant -D 176 404 A2 - ⇒ page 68
❑ To remove crankcase, first remove the transmission ⇒ 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 cover
❑ To drive shaft.
1.1 Poly-V belt - remove and install
Special tools and workshop equipment required
♦ Retaining pin -T10060 A-
♦ Spanner 15 mm AF
1.1.1 Removal
– Remove lower noise insulation from engine ⇒ Rep. Gr. 50 .
– Remove the hose between intercooler/intake flange and the
air mass meter.
– Mark Poly-V belt rotation direction.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
14 Rep. Gr.13 - Crankshaft, pistons
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– Turn tensioning element in arrow direction to relieve tension
on Poly-V belt.
– Lock tensioning element with Retaining pin -T10060A- .
– 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 of Poly-V belt
on the alternador must be the last step.
♦
In vehicles with air conditioning, installation of Poly-V belt last
on the air conditioning compressor.
When the job is finished, always:
– Start the engine and check belt movement.
Belt path for vehicles without air conditioning.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 15
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Belt path for vehicles with air conditioning.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
16 Rep. Gr.13 - Crankshaft, pistons
P
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2 Crankshaft flanges and flywheel - re‐
move and install
Note
Clutch repairs: ⇒ Rep. Gr. 30 .
WARNING
Always replace self-locking nuts and screws subject to angular
torque
1 - Seal
❑ 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 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 and con‐
necting rods
⇒ page 32
4 - Engine flywheel
❑ To remove and install
the flywheel, immobilise
with the Flywheel lock
-3386-
5 - 60 Nm + 90°
❑ Replace after each re‐
moval.
6 - Intermediate plate
❑ Must be positioned on fixing guides.
❑ Do not damage / bend during assembly
7 - 15 Nm
8 - Sealing flange with seal
❑ Complete replacement only.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Crankshaft flanges and flywheel - remove and install 17
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❑ Do not apply additional 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 sleeve -T10053-
♦ Torque wrench - 5 to 50 Nm
(enc. 1/2") -VAG 1331-
♦ Torque wrench - 40 to 200
Nm (enc. 1/2") -VAG 1332-
2.1.1 Removal
– Remove Poly-V belt ⇒ page 14 .
– Remove timing belt ⇒ page 41 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
18 Rep. Gr.13 - Crankshaft, pistons
P
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– Remove crankshaft gear. To do this, immobilise gear with the
Lock -3415- .
– To guide the seal Extractor -3203- , install the gear fastening
screw manually up to the 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 lubricant or grease to the sealing lip of the
oil seal.
– Before installation, remove oil residues from crankshaft trunn‐
ion with a clean cloth.
– Fit the Guide sleeve -T10053/1- onto the crankshaft trunnion.
– Slide oil seal over the Guide sleeve -T10053/1- and over the
end of the crankshaft.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Crankshaft flanges and flywheel - remove and install 19
P
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– 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-
♦ Hand drill plastic brush
♦ Silicone seal -D176404 A2-
♦ Flat spatula
2.2.1 Removal
– Remove Poly-V belt ⇒ page 14 .
– Remove timing belt ⇒ page 41 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
20 Rep. Gr.13 - Crankshaft, pistons
P
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.
– Remove crankshaft gear. To do this, lock gear with 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 must be free of oil and
grease.
2.2.2 Installation
Note
♦
Observe the sealant expiration date.
♦
The sealing flange must be installed within 5 minutes after ap‐
plying the sealant.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Crankshaft flanges and flywheel - remove and install 21
P
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.
– Cut the tube injector on front marking (∅ of injector is approx.
3 mm) .
– Apply silicone sealant, as shown, on the clean sealing surface
of the sealing flange. The sealing compound bead must:
♦ Have a thickness of -arrows-: 2...3 mm.
Note
♦
The sealant bead 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 the
oil seal already installed.
– Tighten fastening screws of sealing flange by using an alter‐
nating tightening sequence. Tightening torque: 15 Nm.
– Remove excess sealant.
– Install crankcase ⇒ page 68 .
Note
After installation, the sealant should dry for approx. 30 minutes
before replenishing the engine with oil.
Install timing belt and adjust distribution times ⇒ page 41 .
– Install Poly-V belt ⇒ page 14 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
22 Rep. Gr.13 - Crankshaft, pistons
P
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o
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c
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.
3 Counterbalance shaft and retaining
frame - remove and install
Note
All bearing and running surfaces must be lubricated before as‐
sembly.
WARNING
Always 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 one
position only. The holes
are displaced.
5 - Fastening sleeve
6 - 20 Nm + 90°
❑ Replace after each re‐
moval.
7 - Gear
❑ For oil pump.
❑ It can be installed in one
position only. The holes
are displaced.
8 - Cover
❑ With sealing tape.
❑ Clean strainer if soiled.
9 - 5 Nm
10 - Sealing ring
❑ Replace.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
3. Counterbalance shaft and retaining frame - remove and install 23
P
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t
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❑ Check it is securely seated.
❑ Lubricate lightly when fitting.
11 - 20 Nm
12 - Oil pump
❑ With 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 that it is firmly seated on the mounting frame.
16 - Engine block
17 - Gear
18 - 20 Nm
19 - Chain tensioning element with tensioning plate.
❑ To remove, immobilise with Locking pin -T10060- .
❑ Remove and install ⇒ page 25 .
20 - 8 Nm + 90°
❑ Replace after each removal.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
24 Rep. Gr.13 - Crankshaft, pistons
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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 side ⇒ page 17 .
– Remove cover securing bolts.
– Remove cover from mounting frame.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
3. Counterbalance shaft and retaining frame - remove and install 25
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– Immobilise chain tensioning element with Retaining pin -
T10060 A- -arrow-.
– Loosen the gear -1- from mounting frame.
– Remove securing bolt --2-- from chain tensioning element and
remove it.
– Remove the chain and put it on a clean surface.
– 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.
– 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.
– Remove counterbalance and counterbalance shaft gear.
– Turn the counterbalance shaft so that it can be removed from
the bearing.
3.1.2 Installing
– Sliding surfaces of the bearing oil.
– Set counterbalance shaft in bearing.
– Fit the gear and counterbalance on counterbalance shaft.
Note
Installing the gear and counterbalance is only possible in a single
position.
– Hand tighten securing bolt for counterbalance weight and
gear.
– Tighten mounting frame to engine block by hand so that there
is no play.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
26 Rep. Gr.13 - Crankshaft, pistons
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Note
♦
When positioning the frame, make sure that the fastening
guide is inserted into the engine block and the O-ring is fitted
in the mounting frame.
♦
Align the mounting frame so that it fits flush with the outer edge
of the engine block on the pulley end.
– Bolt mounting frame 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 bolt -2- of the counterbalance. Tightening
torque: 100 Nm +90°.
Note
The fastening bolt is a tensioning bolt and must always be re‐
placed.
– Install chain tensioning element. Tightening torque: 8 Nm +
90°.
Note
The fastening bolts of the chain tensioning element are tensioning
bolts and must always be replaced.
– Clean chain with a lint-free cloth.
– Ensure that mark on crankshaft sprocket -arrow- is at top.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
3. Counterbalance shaft and retaining frame - remove and install 27
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– Lay chain over crankshaft sprocket, oil pump sprocket and
counterbalance shaft sprocket. Make sure that the marks on
the crankshaft sprocket and counterbalance sprocket align
with the colour-coded chain links -arrows-.
Note
The colour-coded chain links 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 end sealing flange ⇒ page 17 .
– Install counterbalance shaft cover. Tightening torque: 5 Nm.
Note
♦
Before installing cover, lubricate O-ring of oil pump, as well as
shaft on inside of cover
♦
Make sure of the proper seating of sealing strip in cover.
♦
When installing cover, ensure that cover engages in mounting
frame.
– Install crankcase ⇒ page 68 .
– Install and adjust timing belt ⇒ page 41 .
– Install Poly-V belt ⇒ page 14 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
28 Rep. Gr.13 - Crankshaft, pistons
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4 Crankshaft - remove and install
Note
♦
Before removing crankshaft, make sure that a proper surface
has been prepared to ensure that the speed sensor rotor is not
damaged, or does not touch another item.
♦
All bearing and running surfaces 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.
❑ Bearing shell retaining
tabs (block/bearing cap)
4 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For engine block with oil
groove.
5 - Speed sensor rotor
❑ To Engine speed sensor
- G28-
❑ Replace if damaged.
❑ Replace sensor rotor
each time bolts are loos‐
ened
❑ Remove and install.
⇒ page 30
6 - 10 Nm + 90°
❑ Replace after each removal.
7 - Fitted pin
❑ Check the projection from crankshaft ⇒ page 30
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
4. Crankshaft - remove and install 29
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8 - Crankshaft
❑ See notes before removing ⇒ page 29 .
❑ Axial clearance new: 0.07...0.17 mm. Wear limit: 0.37 mm.
❑ Check radial clearance with Plastigage. New: 0.03...00.08 mm. Wear limit: 0.17 mm.
❑ Do not rotate crankshaft while measuring radial clearance.
❑ Crankshaft dimensions ⇒ page 30 .
9 - Stop ring
❑ To engine block, bearing 3.
Check fitted pin 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. Tightening torque: 10 Nm + 90°.
Note
When the bolts are tightened for the second time, the contact
point on the speed sensor rotor is sufficiently deformed to enable
the bolt head to touch -arrows- on the crankshaft -3-, thus ena‐
bling the speed sensor wheel to remain loose under the bolts.
4.1 Crankshaft dimensions
(in mm)
Dimension for fin‐
ishing
Crankshaft trunnion
-∅
Connecting rod
pin-∅
Basic dimension -0,022
54,00
-0,042
-0,022
47,80
-0,042
First rework -0,022
53,75
-0,042
-0,022
47,55
-0,042
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
30 Rep. Gr.13 - Crankshaft, pistons
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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
4. Crankshaft - remove and install 31
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5 Pistons and connecting rods - dis‐
mantle and assemble
Note
All bearing and running surfaces must be lubricated before as‐
sembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
1 - Piston ring
❑ Displace 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.
❑ Replace piston in case
of cracks on its skirt.
❑ Check the piston projec‐
tion at TDC
⇒ page 34
3 - Piston pin
❑ In case of difficulties in
the removal, heat the
piston to 60 °C.
❑ Remove and install with
Puller and fitter -VW 222
A- .
4 - Piston pin retaining ring
5 - Connection rod
❑ Only replace as a set.
❑ Mark correspondence with cylinder -A-.
❑ Mounting position: Marks -B- shall point towards the pulley.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
32 Rep. Gr.13 - Crankshaft, pistons
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6 - Bearing shell
❑ Check installation position.
❑ Check version: Top bearing shell (nearest to the piston) is made with wear-resistant material. Identifi‐
cation: Black line on the bearing shell surface, in the union area.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Distance from the bearing shell edge to the external edge of connecting rod/connecting rod cap: 2.5 mm,
measured from one side.
❑ Check it is securely seated.
❑ Axial clearance. Wear limit: 0.37 mm.
❑ Check radial clearance 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.
11 - Connecting rod screw, 30 Nm + 90°
❑ Replace after each removal.
❑ Lubricate threads and contact surface.
❑ First tighten evenly to 5 Nm.
❑ To measure radial clearance, use old bolts.
Check piston ring gap
– Push ring firmly from above down to approx. 15 mm from bot‐
tom end of cylinder.
Piston ring
Dimensions in mm
New Wear limit
1. compression ring 0,25...0,40 1,0
2. compression ring 0,20...0,40 1,0
Oil scraper ring 0,25...0,50 1,0
Checking ring to groove clearance
Clean groove before check.
Piston ring
Dimensions in mm
New Wear limit
1. compression ring 0,06...0,09 0,25
2. compression ring 0,05...0,08 0,25
Oil scraper ring 0,03...0,06 0,15
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
5. Pistons and connecting rods - dismantle and assemble 33
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Check cylinder diameters
Special tools and workshop equipment required
♦ Precision internal micrometer 50...100 mm
– Take measurements at three different cross positions, in both
lateral -A- and longitudinal -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 flywheel -arrows-.
Piston in cylinder 3.
Larger intake valve chamber towards the pulley -arrow-.
Note
♦
The new correspondence between pistons and cylinders is in‐
dicated by color marking on the piston head.
♦
Piston for cylinders 1 and 2: marking 1/2.
♦
Piston for cylinder 3: marking 3.
Check the piston projection at TDC
Special tools and workshop equipment required
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
34 Rep. Gr.13 - Crankshaft, pistons
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♦ Measurement tool -VW 382/7-
♦ Universal measurement tool -VW 385/17-
Test sequence
– The piston 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 number = -arrow 1-.
♦ Production control code = -arrow 2- (can be disregarded).
♦ Holes = -arrow 3-.
Note
If different figures are obtained when measuring piston projection,
the highest figure should be taken when selecting the head gas‐
ket.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
5. Pistons and connecting rods - dismantle and assemble 35
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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 - Crankshaft, pistons
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15 – Cylinder head, valve control 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 before fitting cylinder
head.
♦
When replacing head, the cooling liquid should be totally re‐
placed too.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 37
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1 - Mechanical distribution up‐
per cover
2 - Timing belt
❑ Before removing, mark
operation direction.
❑ Check wear.
❑ Do not bend.
❑ Remove, install, and ad‐
just ⇒ page 41 .
3 - 10 Nm
4 - 25 Nm
5 - 100 Nm
6 - Camshaft gear
7 - Pulley
❑ With engine phase sen‐
sor wheel.
❑ Use Counter-hold tool -
T10051- to loosen and
tighten.
❑ 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 cover
❑ With oil filler nozzle.
❑ Replace oil filling nozzle if cylinder head cover is damaged.
❑ Before installing, carefully clean the cylinder head sealing surface with a clean cloth.
14 - To turbocharger
15 - 10 Nm
❑ First hand tighten all bolts.
❑ Then tighten both top bolts and thereafter the remainder from the inside outwards, diagonally, according
to the specified tightening torque.
16 - Pressure regulating valve
❑ To crankcase vent.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
38 Rep. Gr.15 - Cylinder head, valve control mechanism
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17 - Oil filling nozzle
❑ Replace.
18 - Cover
❑ Replace seal if damaged.
19 - Gasket
❑ Replace if damaged.
20 - Support
❑ With fuel tube/hose.
21 - Cylinder head cover gasket
❑ Replace if damaged.
22 - 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 blue marked.
❑ Check that it is securely installed.
❑ Fasten with spring braces.
30 - Gasket
❑ Replace.
31 - Support
32 - Hexagonal nut
33 - Cylinder head
❑ Remove and install ⇒ page 46 .
❑ When replacing, renew the complete coolant.
34 - Cylinder head gasket
❑ Replace.
❑ Check marking ⇒ page 40
❑ When replacing, renew the complete coolant.
35 - Glow plug
❑ 15 Nm.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 39
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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 the piston projection. When replacing the cylinder head
gasket, install a new part with the same identification.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
40 Rep. Gr.15 - Cylinder head, valve control mechanism
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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 -10-222A- with Rack -10-222 A/1-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 41
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1.1.1 Removal
Note
Adjustment work on timing belts should only be carried out on cold
engines, as the indicator on the tensioning element changes de‐
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 insulation from engine ⇒ Rep. Gr. 50 .
– Remove the hose between turbocharger and intercooler.
– Carefully cover or seal open ends.
– Remove vibration absorber.
– Remove centre cover of the mechanical distribution.
– Remove mechanical distribution lower cover.
– Rotate the crankshaft to TDC for cylinder 1.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
42 Rep. Gr.15 - Cylinder head, valve control mechanism
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Note
Turn the crankshaft until the mark on the crankshaft pulley is fac‐
ing up and the arrow on the rear section of the timing belt aligns
with shoulder on the phase sensor wheel hub -arrows-.
– Immobilise hub with Mandrel -3359- . To do this, slide mandrel
through free elongated hole on left side and into hole in cylin‐
der head.
– Lock timing belt gear at crankshaft, using Crankshaft stop -
T10050- . 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
gear can be moved into the elongated holes.
– Turn Pin wrench -3387- counterclockwise (opposite direction
of arrow) until the timing belt tensioning element can be fixed
in place using Locking pin -T10115- .
– Now, turn Pin wrench -3387- clockwise in direction of -arrow-
until stop and remove timing belt first from the water pump,
and then from the remaining gears.
1.1.2 Installation
Note
Adjustment work on timing belts shall only be carried out on cold
engines, as the indicator on the tensioning element changes de‐
pending on the engine temperature.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 43
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– Turn camshaft gear counterclockwise in the elongated holes
- in the direction of arrow - until reaching stop.
– Install timing belt at crankshaft gear, tensioning element and
camshaft gear.
Note
Make sure the tensioning element is correctly seated in rear me‐
chanical distribution guard -arrow-.
– Now, turn the tensioning element, using the Pin wrench - 3387-
in the direction of -arrow- until reaching the stop, and fit timing
belt on the water pump.
– Relieve the tension from the tensioning element by turning it
with the Pin wrench -3387- in opposite direction of arrow.
– Now, carefully turn tensioning element with 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 cylinder 1.
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
/
4
turn in the reverse direction in order to
readjust TDC of cylinder 1. No correction is allowed while the
engine is turning, so as to ensure the correct operation of the
crankshaft stop.
– Once the Crankshaft stop -T10050- has engaged, check
whether the gear can be locked by using the Locking pin
-3359- .
If the hub cannot be locked:
– Pull the Crankshaft stop -T10050- out of the hole in the sealing
flange and turn the crankshaft until the gear can be locked with
the Locking pin -3359- .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
44 Rep. Gr.15 - Cylinder head, valve control mechanism
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– Loosen fastening screws of camshaft gear -1-.
– Turn slightly the crankshaft in the opposite direction of the en‐
gine rotation until the Crankshaft stop -T10050- is positioned
in front of the hole at sealing flange -arrow-
– Now, turn the crankshaft in the engine rotation direction until
the crankshaft stop pin locks in the sealing flange while turn‐
ing.
– Tighten fastening screws of the camshaft gear to 25 Nm.
– Remove mandrel -3359- and 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
/
4
turn in the reverse direction in order to
readjust TDC of cylinder 1. No correction is allowed while the
engine is turning, so as to ensure the correct operation of the
crankshaft stop.
– Repeat checking.
– Install the lower cover of the mechanical distribution and the
vibration absorber.
– Install mechanical distribution centre cover.
– Install mechanical distribution upper cover.
– Install engine support and console. Torque setting ⇒ page 8 .
– Install Poly-V belt ⇒ page 14 .
– Install the hoses between intercooler and turbocharger, and
between intercooler and intake connecting flange.
– Install engine noise insulation ⇒ Rep. Gr. 50 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 45
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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 timing belt ⇒ page 41 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
46 Rep. Gr.15 - Cylinder head, valve control mechanism
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Note
Since the lifting eyes are located on the cylinder head, an addi‐
tional support should be fastened 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.
– Remove spindle -A-.
– Before removing cylinder head, drain fuel at auxiliary pump
using Manual vacuum pump -V.A.G 1390- with the Fluid re‐
ceptacle -V.A.G 1390/1- ⇒ page 97 .
– Follow the sequence indicated when loosening or tightening
the cylinder head screws.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 47
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1.2.2 Installation
Note
♦
Always replace head screws.
♦
In cases of repair, carefully remove gasket remains from cyl‐
inder head and engine block. Ensure that no long grooves or
scratches are created. When using sand paper, do not use
less than 100 grade.
♦
Carefully remove emery and abrasive remains.
♦
Only remove new cylinder head gasket from packaging prior
to installation.
♦
Handle gasket extremely 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 follows:
– 1. Previous tightening with torque meter:
1st stage (torque) 40 Nm
2nd stage (torque) 60 Nm
– 2. Tighten with normal spanner:
3rd stage (angular torque) 90°
4th stage (angular torque) 90°
Note
No retightening of the cylinder head is required after repairs.
– After tightening the cylinder head, turn the camshaft so that all
the cams in cylinder 1 are turned equally upwards. Before
mounting the cylinder head, turn the crankshaft in the engine
rotation direction until TDC ⇒ page 41 .
– Perform test drive and check fault memory ⇒ page 115 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
48 Rep. Gr.15 - Cylinder head, valve control mechanism
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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.
– Remove all glow plugs, using U/J extension and socket, 10
mm -3220- .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cylinder head - remove and install 49
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– Install the Adapter -V.A.G 1381/12- in place of the glow plugs.
– Check compression 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, eliminate possible present failures and,
then, erase fault memory ⇒ page 115 .
Note
Removing the central connector from unit injectors causes faults
to be recorded. Therefore, check the fault memory and erase it,
when required.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
50 Rep. Gr.15 - Cylinder head, valve control mechanism
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2 Valve command - repair
Note
♦
Cylinder heads with cracks between the valve seats can still
be used without reducing their useful life when such cracks
are small, maximum 0.5 mm wide.
♦
All bearing and running surfaces must 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 interchange.
❑ With hydraulic offsetting
of valve gap.
❑ Store with cam lobe
contact surface down‐
wards.
❑ Check camshaft axial
clearance before instal‐
ling ⇒ page 52
❑ Lubricate contact sur‐
face.
❑ Before removing, re‐
move the camshaft
bearing caps.
6 - Keys
7 - Valve spring upper plate
8 - Valve spring
❑ Removing and installing: Cylinder head removed: with Compressor device -2037- mounted
⇒ page 56 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Valve command - repair 51
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9 - Valve internal spring
❑ Removing and installing: Cylinder head removed: with Compressor device -2037- mounted:
⇒ page 56 .
❑ Install in the cylinder head before putting the bearing caps.
10 - Valve stem seal
❑ Replace ⇒ page 56 .
11 - Valve guide
❑ Check ⇒ page 55 .
12 - Injection unit
❑ Remove and install ⇒ page 112 .
13 - Cylinder head
❑ See note ⇒ page 51 .
❑ Rework valve seats ⇒ page 53
14 - Oil seal
❑ 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 and cylinder head.
17 - Camshaft
❑ Check axial clearance ⇒ page 52
❑ Remove and install ⇒ page 58 .
❑ Check radial clearance with Plastigage. Wear limit: 0.11 mm.
❑ Excentricity: max. 0.01 mm.
❑ Valve identification and synchronization ⇒ page 53
18 - Bearing cap
❑ Installation sequence ⇒ page 58 .
❑ Bearing cap 4 is identified as bearing cap 5.
❑ When installing, use Sealant -AMV 17400401- to seal surfaces of bearing caps 1 and 4, which contact
cylinder head
19 - 8 Nm + 90°
❑ Replace after each removal .
Check camshaft axial clearance
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
52 Rep. Gr.15 - Cylinder head, valve control mechanism
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Special tools and workshop equipment required
♦ Support -VW 387-
♦ Dial gauge
Check with tappets removed and with bearing caps installed.
Wear limit: max. 0.15 mm.
Seal the contact surfaces of bearing caps 1 and 4 of camshaft,
with Sealant -AMV 17400401- .
Apply 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- = ∅ 52.8 mm.
♦ Identification via numbers and letters on the external cam sur‐
face of the escape valve at cylinder 3:
Cylinder 3 -arrow- 1 R
Valve synchronization in the opening of 1-mm valve
Intake opens after TDC 15,8°
Intake closes after BDC 25,3°
Exhaust opens before BDC 28,2°
Exhaust closes before TDC 18,7°
2.1 Valve seats - rework
Special tools and workshop equipment required
♦ Depth gauge
♦ Valve seat recovery tool
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Valve command - repair 53
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Note
♦
In case of repairs to engines with leaking valves, simply re‐
working or replacing the seats and valves is insufficient. Es‐
pecially in engines with high milage, the valve guides must
also be checked for wear.
♦
The valve seats should only be sufficiently reworked to pro‐
duce a perfect seating pattern. The maximum reworking di‐
mension must be calculated before undertaking the 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 engine
head upper edge.
– Calculate max. permissible reworking dimension from meas‐
ured distance -a-and minimum dimension.
Minimum dimensions: Intake valve 43.4 mm Escape valve 43.2
mm.
Distance measured minus minimum distance = maximum per‐
mitted reworking dimension.
Example:
- Measured distance
Minimum dimension
44,1
43,4
mm
mm
= Max. reworking dimension perm. 0,7 mm
2.1.2 Reworking intake valve seat
a =∅35.7 mm
b = 1.6 mm
45° = Valve seat angle
Note
. The 30° angle in the valve seat base is crucial for ensuring the
correct gas flow.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
54 Rep. Gr.15 - Cylinder head, valve control mechanism
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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 guides.
– Determine tilting clearance. Wear limit: max. 1.3 mm.
– Cylinder head shall be replaced if the clearance is greater than
wear limit.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Valve command - repair 55
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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
interchanged.
– Adjust piston of respective cylinder to top dead centre (TDC).
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
56 Rep. Gr.15 - Cylinder head, valve control mechanism
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– 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 the new valve stem seal in the Fitter -3129- .
– Lubricate the seal lip at valve stem and tighten it carefully on
the valve guide.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Valve command - repair 57
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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 screws of camshaft gear -1-.
– Remove hub camshaft gear.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
58 Rep. Gr.15 - Cylinder head, valve control mechanism
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– Loose hub fastening screw -1-.
– Use Blocking device -T10051- .
– Loosen hub securing screw about 2 turns.
– Install Puller -T10052- and align it with holes in hub.
– Install securing screws -1- into hub.
– Apply effort to the hub by tightening evenly screw -2- until the
hub is separated from the tapered section of the camshaft.
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 diagonally.
Note
Bearing cap 4 is identified as bearing cap 5.
2.4.2 Installation
Note
♦
When installing the camshaft, the cams for cylinder 1 should
point upwards.
♦
Do not interchange used bearing shells (mark them).
♦
When installing the camshaft, ensure the proper clip seating
on the bearing caps and cylinder head.
♦
Before installing bearing caps, ensure that cylinder head bolt
washers are fitted in the cylinder head.
– Lubricate contact surfaces of shell bearings.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Valve command - repair 59
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– Tighten bearing caps 2 and 3 alternately and diagonally to 8
Nm + 90° (replace).
– Install bearing caps 1 and 4, and also tighten to 8 Nm + 90°
(replace).
Note
♦
Bearing cap 4 is identified as bearing cap 5.
♦
Apply Sealant -AMV 17400401- to seal surfaces of bearing
caps 1 and 4, which are in contact with the cylinder head
♦
Bearing cap 4 must align flush with outer edge of cylinder
head, because otherwise leaks may develop at the auxiliary
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 Nm.
– Use Blocking device -T10051- .
– Install camshaft gear on the hub.
Note
Toothed segment -arrow- of camshaft shall be on the top.
– Align camshaft gear in central position on elongated holes.
– Tighten manually the fastening screws -1- of the camshaft
gear in order not to have play.
– Immobilise hub with Mandrel -3359- .
– Install and adjust timing belt ⇒ page 41 .
– Install auxiliary pump ⇒ page 97 .
Note
When new tappets have been installed, do not start the engine
for about 30 minutes. Hydraulic compensation elements must knit
together (otherwise, valves will knock pistons).
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
60 Rep. Gr.15 - Cylinder head, valve control mechanism
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17 – Lubrication system
1 Lubrication system components - re‐
move and install
Note
♦
When a significant number of metal chips and shavings ap‐
pear in the 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 pressure ⇒ page 70 .
Oil system capacity:
with oil filter 4.2 l.
Engine oil specification:
Only use engine oils as per VW 505.01specification.
Part I assembly overview ⇒ page 61 .
Part II oil filter support disassembly ⇒ page 64 .
Part III: oil supply tube removal and installation ⇒ page 65 .
Part I
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 61
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1 - 15 Nm
2 - Flange
❑ With sealing ring.
❑ Must be located on se‐
curing guides.
❑ Remove and install
⇒ page 17 .
❑ Install with Silicone
sealant -D 176 404 A2 -
⇒ page 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 di‐
agonally.
7 - Oil dipstick
❑ The oil level should exceed the maximum marking!
❑ Marks ⇒ page 66
8 - Guide
❑ Remove to drain oil.
9 - 5 Nm
10 - Guide tube
11 - 10 Nm
❑ Not applicable.
12 - Sealing ring
❑ Replace.
❑ Check it is securely seated.
❑ Lubricate lightly when fitting.
13 - Cover
❑ With sealing tape.
❑ Clean filter if dirty.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
62 Rep. Gr.17 - Lubrication system
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14 - 20 Nm
15 - Oil pump
❑ With 11.5-bar pressure relief valve.
❑ Before installing, check whether the centering guides are mounted.
16 - Fastening sleeve
17 - 25 Nm
❑ Install without sealant.
18 - Mounting frame
❑ Before installing, check the centering guides in the engine block are in their positions, and the ring is
inserted in the mounting frame.
❑ Remove and install ⇒ page 23 .
19 - Oil ejector
❑ For piston cooling.
❑ Check installation 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 .
24 - Packing
❑ Replace.
25 - Plug, 30 Nm
❑ Replace the plug with seal.
26 - Gear
❑ To oil pump.
❑ It can be installed in one position only.
27 - 20 Nm + 90°
❑ Replace after each removal.
28 - Chain
❑ Observe fastening position ⇒ page 23 .
29 - Gear
❑ To counterbalance shaft.
❑ It can be installed in one position only. The holes are displaced.
30 - 100 Nm + 90°
❑ Replace after each removal.
❑ The angular torque can be performed in several stages.
❑ To loose and tighten, use Multi-point spanner -T10061-
31 - Counterbalance
❑ It can be installed in one position only. The holes are displaced.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 63
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32 - 20 Nm
33 - Gear
34 - 8 Nm + 90°
❑ Replace after each removal.
35 - Chain tensioning element with tensioning plate.
❑ To remove, immobilise 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
❑ Replace.
5 - Connection, 25 Nm
❑ To the turbocharger oil
supply tube.
6 - Oil supply tube
❑ For the turbocompres‐
sor.
❑ Remove and install
⇒ page 65 .
7 - Oil pressure switch -F1- 0.7
bar, 20 Nm
❑ In case of leakage, cut
and replace the sealing
ring.
❑ Checking ⇒ page 70 .
8 - Sealing cap, 25 Nm
9 - Sealing ring
❑ Replace.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
64 Rep. Gr.17 - Lubrication system
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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 turbocharger.
6 - Clip
7 - 25 Nm
❑ Replace.
8 - Support
9 - 10 Nm
10 - 10 Nm
11 - Connection
❑ Remove and install
⇒ Item 20 (page 103) .
12 - Turbocharger
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 65
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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.
– To remove, loosen supply hose clips -6-.
– Disconnect safety nut -1- on oil filter bracket -4-, locking the
connection -2-.
– Remove bolt -10- at rear side of engine.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
66 Rep. Gr.17 - Lubrication system
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– 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- on connection -2- of the oil
filter bracket -4-.
– Manually tighten the safety nut -1- on connection -11- of tur‐
bocharger -12-.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 67
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– Tighten safety nut -1- on oil filter bracket -4-, to the tightening
torque, locking the connection -2-.
– Tighten safety nut -1- on turbocharger -12-, to the tightening
torque, locking the connection -11-.
– Position clips -6- on oil supply tube -5-.
– Tighten bolt -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 remain on engine block with a
flat spatula.
– Eliminate sealant residues from crankcase and its cover with
a rotary brush, like a plastic brush attached to a portable drill
(wear eye protection).
– Clean the sealing surfaces. They must be free of oil and
grease.
1.1.2 Installation
Note
♦
Check the sealant expiration date.
♦
The crankcase must be installed within 5 minutes after apply‐
ing the sealant.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
68 Rep. Gr.17 - Lubrication system
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– Cut the tube injector on front marking (∅ of injector is approx.
3 mm) .
– Apply 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.
– Install transmission ⇒ Rep. Gr. 34 .
– Tighten crankcase/transmission screws to 45 Nm.
Note
After installing the crankcase, the sealant should dry for approx‐
imately 30 minutes before replenishing with engine oil.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 69
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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 diagrams, Electrical fault finding and
Fitting locations
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
70 Rep. Gr.17 - Lubrication system
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Test sequence
– Remove the Oil pressure switch -F1- and screw it to the 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 increasing speed. At 2000 rpm and an oil tempera‐
ture of 80°C, the oil pressure should be at least 2.0 bar.
At higher speeds, oil pressure may not exceed 5.8 bar. If neces‐
sary, replace the oil filter support.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Lubrication system components - remove and install 71
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19 – Cooling system
1 Cooling system components - re‐
move and install
Note
♦
The cooling system 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 Adapter for VAG 1274 -VAG
1274/8- and the Adapter for VAG 1274 -VAG 1274/9- .
Cooling system components in the body ⇒ page 73 .
Cooling system components in the engine ⇒ page 74 .
Cooling system - drain and replenish ⇒ page 76 .
Coolant mixture proportions ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
72 Rep. Gr.19 - Cooling system
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1.1 Cooling system components in the body
1 - Radiator
❑ Remove and install
⇒ page 79 .
❑ When replacing,
change the complete
coolant.
2 - Sealing ring
❑ Replace if damaged.
3 - Upper cooling 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
❑ For radiator fan connector.
14 - Lower cooling system hose
❑ Hose connection diagram ⇒ page 75 .
15 - Radiator fan thermal switch -F18- , 35 Nm
❑ For electric fan.
❑ Starting temperatures: Stage 1 ON: 92...97 °C OFF: 84...91 °C. Stage 2 ON: 99...105 °C OFF: 91...98 °
C.
16 - Radiator lower support
❑ Black.
17 - 5 Nm
18 - Radiator upper support
❑ White.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cooling system components - remove and install 73
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1.2 Cooling system components in the engine
1 - Hose
❑ To heat exchanger.
2 - Connection
3 - 10 Nm
4 - Hose
❑ From the heat exchang‐
er.
❑ Hose connection dia‐
gram ⇒ page 75 .
5 - 25 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 ⇒ page 75 .
13 - Connection
❑ For thermostat.
14 - 15 Nm
15 - Thermostat
❑ Remove and install ⇒ page 82 .
❑ Check installation position ⇒ page 82 .
❑ Checking: heat thermostat in water.
❑ The opening starts at approximately 85°C.
❑ And ends at approximately 105 °C.
❑ Min. open lifting 7 mm.
16 - Water pump
❑ Check ease of movement.
❑ Check installation position.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
74 Rep. Gr.19 - Cooling system
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❑ 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
❑ For exhaust gas recircu‐
lation.
6 - Radiator
7 - Oil radiator
8 - Water pump/thermostat
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cooling system components - remove and install 75
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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 cover is
removed. Cover it with a cloth and open carefully.
– Remove lower noise insulation from engine ⇒ Rep. Gr. 50 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
76 Rep. Gr.19 - Cooling system
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– 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 system components - remove and install 77
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1.4.2 Replenish
Note
♦
Use only purple-colour Additive -G12- for the cooling system,
in compliance with TL VW 774 F.
♦
The Additive -G12- and the additives for the cooling system
which indicate "compliant with TL VW 774 D" , prevent dam‐
ages due to corrosion, freezing or mould formation, further
increasing the boiling temperature of the coolant. For this rea‐
son, the cooling system should always (all the year round)
contain the described antifreeze and anti-corrosive product
mixture.
♦
The purple Additive -G12- (as per TL VW 774 F) can be mixed
with the previous red Additive -G12- !
♦
Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦
Antifreeze protection must 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 limit of 60 % (anti-freeze
protection up to -40 °C). Where the proportion is greater, the
cooling capacity and antifreeze protection will diminish.
♦
When replacing the radiator, heat exchanger, cylinder head or
cylinder head gasket, used coolant should not be reused.
Recommended mixture proportions:
Antifreeze pro‐
tection until
Antifreeze pro‐
portion
G 12
2)
Water
2)
-25 °C
-35 °C
40 %
50 %
2.0 l
2.5 l
3.0 l
2.5 l
2) The coolant volume may vary according to the equipment on each vehicle.
– Close the cooling system drainage plug.
– Connect cooling fluid hose to oil radiator.
– Install engine noise insulation ⇒ Rep. Gr. 50
With Cooling system supply unit -VAS 6096- :
– Install the Engine cooling system tester -VAG 1274- adapter,
according to the vehicle, in the coolant reservoir.
– Fill the cooling system circuit with the Cooling system supply
unit -VAS 6096- ⇒ Operation instructions for the Cooling sys‐
tem supply unit -VAS 6096- .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
78 Rep. Gr.19 - Cooling system
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Without Cooling system supply unit VAS 6096 -VAS 6096- :
– Fill with coolant up to the maximum mark on the expansion
reservoir.
– Replace the coolant reservoir 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 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-
1.5.1 Removal
– Remove front bumper ⇒ Rep. Gr. 63 .
– Put front panel in the work position: ⇒ Rep. Gr. 50 .
– Drain the cooling system ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cooling system components - remove and install 79
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– Remove cooling system hoses from radiator
– Disconnect thermal switch and fan connectors from radiator.
– Remove 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 information and instruc‐
tions ⇒ page 8 .
1.6 Water pump - 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-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
80 Rep. Gr.19 - Cooling system
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1.6.1 Removal
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 torque: 15 Nm.
Note
The pump plug must face downwards.
– Install and adjust timing belt ⇒ page 41 .
– Install Poly-V belt ⇒ page 14 .
– Fill cooling system ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cooling system components - remove and install 81
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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 alternator ⇒ Rep. Gr. 27 .
– Remove the cooling system hose from the connection flange.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
82 Rep. Gr.19 - Cooling system
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– Loosen fastening screws -1- from connection 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 thermostat must be almost vertical.
– Mount the connection flange -2- with thermostat -4- into engine
block.
– Tighten securing bolts -1-. Tightening torque 15 Nm.
– Fill cooling system ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Cooling system components - remove and install 83
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20 – Supply system - Fuel tank, fuel pump
1 Fuel supply system components - re‐
move and install
Note
♦
The hose connections are fastened by spring clamps or bra‐
ces.
♦
Always replace fastening clamps with spring-type clamps.
♦
To install spring clamps, we 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 install ⇒
Rep. Gr. 55 .
6 - Vent valve
❑ Checking ⇒ page 86
❑ To remove valve, open
the clip sideways to the
outside of the support.
❑ To remove and install,
remove the fuel filling
pipe.
7 - Gravity valve
❑ To remove, remove the
right rear wheel case
cover.
❑ To remove, release
locking tab and loosen
the valve upwards out of
filler nozzle.
❑ Check valve passage.
Vertical valve: open,
valve inclined at 45°:
closed.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
84 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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8 - Fuel supply tube
9 - Spring-type clamp
10 - Fuel tank
❑ Support with Engine/gearbox jack -VAG 1383A- when removing.
❑ Remove and install ⇒ page 88 .
11 - 26 ± 3 Nm
12 - Vent hose
❑ Check that it is securely connected.
13 - Vent hose
❑ To gravity valve.
❑ Check that it is 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 5321/9-
19 - Supply tube
❑ To fuel filter ⇒ Item 1 (page 87) .
❑ Secured with clip to the fuel tank.
❑ Check that it is securely connected.
❑ Black.
❑ Press the release button in the connection piece for removing the flange.
20 - Return pipe
❑ Blue or blue marked.
❑ Secured with clip to the fuel tank.
❑ Check that it is securely connected.
❑ To remove the flange, press the release button in the connection piece.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 85
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1 - To pressure relief valve.
2 - To gravity 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 fastened to fuel tank.
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.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
86 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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1.2 Fuel filter - repair
1 - Supply tube
❑ From the fuel tank.
❑ White or with white
marking.
❑ Check that it is securely
connected.
2 - Return pipe
❑ Blue or blue marked.
❑ Check that 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 auxiliary pump.
❑ Check it is securely
seated.
❑ Blue or blue marked.
6 - Fuel pipe
7 - Cooling system hose
8 - Fuel temperature sensor -G81-
9 - Cooling system hose
10 - Fuel filter
❑ Fill with diesel before installing.
❑ Flow direction is identified with an arrow.
❑ Do not interchange the connections.
❑ Replace if damaged.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 87
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1.3 Safety measures for working on the fuel
supply system
WARNING
During assembly work especially within the engine compart‐
ment, due to the lack of space, bear in mind the following:
♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter
system, cooling system and cooling gas, brake fluid, vac‐
uum) and electric cables must be restored to their original
positions.
♦ To provide easy access to all the moving or hot parts.
When removing or installing fuel level sensor or fuel pump, with
fuel tank full or partially full, observe the following:
When removing or installing fuel level sensor or fuel pump, in the
fuel tank full or partially full, observe the following:
WARNING
♦ The fuel and hoses in the fuel system may be very hot
( risk of burns)!
♦ Fuel system is under pressure!
♦ Use protective gloves and eyewear when 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 m
3
/ hour.
♦ Avoid skin contact with fuel! Use fuel resistant gloves!
1.4 Cleanliness rules
For jobs on the fuel / injection system, strictly observe the follow‐
ing “6 cleaning” rules:
♦ Carefully clean all the connections and surrounding areas be‐
fore disconnecting them.
♦ Place all the parts removed on clean surface and cover them.
Do not use cloth that releases lint!
♦ If repair work is not to be carried out immediately, open com‐
ponents must be covered up or carefully preserved.
♦ Install only clean components. Only remove spare parts from
packaging just prior to installation. Do not install components
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 that may come into contact with fuel must be
cleaned immediately. Damaged hoses should be replaced.
1.5 Fuel tank - remove and install
Special tools and workshop equipment required
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
88 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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♦ 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, disconnect battery earth strap.
– Fold rear seat forwards.
– Remove fuel pump access cover.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 89
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WARNING
♦ The fuel and hoses in the fuel system may be very hot (risk
of burns)!
♦ Fuel system is under pressure!
♦ Use protective gloves and eyewear when performing any
repairs on the fuel system!
– Drain fuel tank.
– Disconnect return -1- and supply -2- pipes, and the fuel tank
connector -3-.
Note
Press locks on pipe connectors to disconnect them.
– Exhaust system must be lowered a bit, and fastened to the
body with a metallic wire.
– Remove heat deflector between the exhaust tube and the fuel
tank.
– Remove fastening clips from the supply pipe by using the
Standart-type clamp pliers -VAS 5024A- .
– Support the fuel tank by using the Engine/gearbox combo jack
-VAG 1383A- .
– Remove fuel tank securing bolts.
– Lower fuel tank.
1.5.2 Installation
Installation is carried out by inverting the removal sequence, ob‐
serving the following:
♦ Vent and fuel hoses are to be installed kink-free.
♦ Check the firm seating of the fuel hoses.
♦ Do not interchange supply and return lines (return hose blue
or with blue marking, supply line black).
Note
After installing fuel meter sensor, check that supply, return and
vent pipes are still fixed to the fuel tank.
Flange mark shall be aligned with fuel tank mark -arrow-.
Blue or blue marked return pipe -1- connected to connection with
mark -R-.
Black supply pipe -2- connected to connection with mark -V-.
Note
After fuel pump flange installation, check if supply, return and vent
pipes are still fixed to fuel tank.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
90 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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1.6 Fuel pump - remove 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-
1.6.1 Removal
Follow safety measures ⇒ page 88 .
Follow cleanliness rules ⇒ page 88 .
– Check if the vehicle has code radio; if so, request respective
anti-theft code.
– With ignition off, disconnect earth strap from battery.
– Fold rear seat forwards.
– Remove fuel pump access cover.
– Disconnect return -1- and supply -2- pipes, and the fuel tank
connector -3-.
Note
Press locks on pipe connectors to disconnect them.
WARNING
♦ The fuel and hoses in the fuel system may be very hot (risk
of burns)!
♦ Fuel system is under pressure!
♦ Use protective gloves and eyewear when performing any
repairs on the fuel system!
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 91
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– Loosen the pump with Spanner -VW 5321/9 - or Spanner -
T10334- .
– Remove fuel pump and seal fuel tank opening.
Note
When the fuel pump is to be replaced, drain it before discarding.
1.6.2 Installation
Installation is carried out by inverting the removal sequence, ob‐
serving the following:
Note
♦
Do not fold fuel level sensor when installing.
♦
Insert flange sealing or the dry fuel pump into the fuel tank
opening.
♦
Moisten the seal with fuel only when installing the flange or
fuel pump.
♦
Make sure the fuel pipes are firmly seated.
♦
After installing the fuel pump flange, check whether the supply,
return and vent pipes are still fastened onto the fuel tank.
♦
Flange mark shall be aligned with fuel tank mark -arrow-.
1.7 Fuel meter sensor - remove and install
1.7.1 Removal
– Remove fuel pump ⇒ page 91 .
– Release and remove the terminals of the wires -3- and -4-.
– Raise retaining locks -1- and -2- with a screwdriver and pull
the fuel level sensor out and downwards -arrow-.
1.7.2 Installation
– Insert fuel level sensor in the fuel pump guides and push up
until it engages.
1.8 Fuel pump - check
Special tools and workshop equipment required
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
92 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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♦ Portable multimeter -VAG 1526C- or Multimeter -V.A.G 1715-
♦ Auxiliary cable set -V.A.G 1594 A-
♦ Test probe -VAG 1527B-
Test conditions
• The fuses must be in order.
• The battery voltage must be at least 11.5 V.
• All power consuming components, like lights and rear window
demister, must be off.
Check operation and power supply 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 does not light ON:
– Locate and repair cable interruption, according to the current
circuits scheme. ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
If the LED lights ON (power supply OK).
– Remove fuel pump ⇒ page 91 .
– Check if cables are connected between flange and fuel pump.
In case there is no cable interruption:
– Replace fuel pump ⇒ page 91 .
Check current consumption at fuel pump
– Remove 4-pin connector from the fuel pump flange.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 93
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– Set multimeter measuring range to 20 A, and using auxiliary
cables from -V.A.G 1594 A- , connect multimeter in series be‐
tween the contacts -1- of the connector and fuel pump.
Note
The 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:
– Replace fuel pump ⇒ page 91 .
1.9 Accelerator mechanism - repair
1 - Support
❑ Remove and install ⇒
Rep. Gr. 46 .
2 - Connector
❑ Black, 6-pin.
3 - Accelerator pedal position
sensor -G79-
❑ Not adjustable.
❑ Accelerator pedal posi‐
tion sensor transmits
the pedal position to en‐
gine command unit.
❑ Remove feet rest area
cover to remove sensor.
4 - 10 Nm
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
94 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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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 blocked.
• The check valve in the fuel supply hose must be in order.
Test sequence
– Remove plug -arrow-.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 95
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– Connect Auxiliary pump tester -VAS 5187- , as shown.
– Start engine and run at idle speed.
– Connect the Diagnosis, Measurement 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: at least
3.5 bar.
– Press the ← key.
– Select function 06 End the test function key.
– Switch off ignition.
If the specification is not obtained:
– Replace auxiliary pump ⇒ page 97 .
Note
After removing pressure gauge unit, tighten plug at 25 Nm. Al‐
ways replace seal.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
96 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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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 - Edition 02.2009
1. Fuel supply system components - remove and install 97
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1.11.1 Removal
– 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 ➤
3 - Cyl. diesel engine - Edition 02.2009
98 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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– Install auxiliary pump and tighten upper securing bolts to 20
Nm.
– 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 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Fuel supply system components - remove and install 99
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.
– Unscrew pressure regulating valve -2- and close valves -3-
and -4-.
– 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.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
100 Rep. Gr.20 - Supply system - Fuel tank, fuel pump
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.
21 – Overcharge - turbo
1 Overcharge system with turbocharg‐
er
1.1 Safety measures
WARNING
During assembly work, especially within the engine compart‐
ment, due to the lack of space, bear in mind the following :
♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter
system, cooling system and cooling gas, brake fluid, vac‐
uum) and electric cables must be restored to original
positions.
♦ To provide easy access to all the 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
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 areas be‐
fore disconnecting them.
♦ Place all the parts removed on clean surface and cover them.
Do not use cloth that releases lint!
♦ If repair work is not going to be carried out immediately, open
components should be covered up or carefully 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.).
♦ During repair services, remove oil from hose connections and
ends.
♦ With system open: If possible, avoid using compressed air. If
possible, do not move the vehicle.
1.3 Turbocharger - remove and install
Follow safety measures ⇒ page 101 .
Follow cleanliness rules ⇒ page 101 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Overcharge system with turbocharger 101
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Note
♦
All the hoses are fastened with clamps or coupling fittings.
♦
When installing spring clamps, use Standart-type clamp pliers
-VAS 5024A- .
♦
Do not install hoses 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 with coupling connections
Note
All the overcharge system hoses are fastened with spring clamps
or connections. Always check the following points in the connec‐
tions:
– Release the connection by pulling the fixing clip -arrow-, with‐
out using tools.
– When assembling, make sure the retaining tabs -A- are firmly
secured.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
102 Rep. Gr.21 - Overcharge - turbo
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.
1 - Exhaust manifold
❑ With turbocharger of ex‐
haust gases.
❑ Full replacement only.
❑ To remove, first remove
the hose between the
turbocharger/air mass
meter, intake manifold/
intercooler hose, input
flange with exhaust 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
❑ Replace.
14 - Hose
❑ To Electromagnetic valve for limiting charge pressure -N75- .
15 - Oil return pipe, 30 Nm
❑ To engine block.
16 - 15 Nm
17 - Gasket
❑ Replace.
18 - Front exhaust pipe
19 - 25 Nm
❑ Replace.
20 - Connection, 30 Nm
❑ Replace.
❑ Apply -G 052 112 A3- on the threads and contact surface of the screw head.
❑ Fill turbocharger with engine oil before installing the oil supply tube.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Overcharge system with turbocharger 103
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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 additive). Do
not use sliding agents containing oil.
♦
When repairing, remove oil from the hose connections and
ends.
♦
Overcharge system must be free of leaks.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
104 Rep. Gr.21 - Overcharge - turbo
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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
16 - Support
❑ From tube.
❑ Bolted to crankcase.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Overcharge system with turbocharger 105
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.
23 – Supply system - mechanical injection (diesel)
1 Maintaining the direct injection Diesel
system
The direct injection diesel system command unit has a fault mem‐
ory. Before performing repairs, and for fault location, refer to the
fault memory ⇒ page 115 .
Safety measures ⇒ page 107 .
Cleaning rules ⇒ page 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
clutch pedal.
D - Fuel pressure regulator
❑ In fuel pump.
1 - Valve blocking
❑ Vacuum hose connec‐
tion diagram
⇒ page 121 .
2 - Exhaust gas recirculation
valve (mechanical)
❑ With intake manifold
valve.
3 - Pressure regulating valve
❑ To crankcase vent.
4 - Intake manifold
❑ Intake manifold pres‐
sure sensor -G71- with
Intake manifold temper‐
ature sensor -G72- .
5 - Direct injection diesel sys‐
tem control unit -J248-
❑ With Altitude sensor -F96- .
❑ Replace ⇒ page 115 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
106 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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6 - Air mass meter -G70-
7 - Air filter
8 - Auxiliary pump
❑ Check ⇒ page 95 .
9 - Vacuum pump
10 - Connector
❑ For Pump / injector valve of cylinder 1 -N240- ... Pump / injector valve of cylinder 4 -N243- .
11 - Fuel temperature sensor -G81-
12 - Engine speed sensor -G28-
13 - Thermostat valve
14 - Glow plugs
15 - Hall Sensor -G40- Hall (G40) Sensor
❑ For the camshaft position.
16 - Fuel filter
1.2 Safety measures
WARNING
During assembly work, especially within the engine compart‐
ment, due to the lack of space, bear in mind the following:
♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter
system, cooling system and cooling gas, brake fluid, vac‐
uum) and electric cables must be restored 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
activate in case of accident.
To prevent injuries to persons and/or damages to the injection
system and glow plugs, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting test cables for injection and glow plugs.
♦ If the engine is to be turned over at starting speed, without
starting, e.g. to check compression, disconnect injector con‐
nector on cylinder head.
♦ Check if the vehicle has code radio; if so, request respective
anti-theft code before disconnecting the battery.
♦ Only disconnect and connect the battery when the ignition is
switched off; otherwise, the direct injection diesel command
system unit may be damaged.
1.3 Cleanliness rules
When servicing the fuel supply/injection system, pay attention to
the following cleanliness rules:
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Maintaining the direct injection Diesel system 107
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♦ Carefully clean all the connections and surrounding areas be‐
fore disconnecting them.
♦ Place all the parts removed on clean surface and cover them.
Do not use cloth that releases lint!
♦ If repair work is not to be carried out immediately, open com‐
ponents opened must be covered up or carefully 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 must be cleaned im‐
mediately. Damaged hoses should be replaced.
1.4 Intake manifold valve - repair
The intake manifold valve closes for approx. 3 seconds when
stopping the engine, and then opens again. This reduces the stop
jerking movement.
1 - Intake manifold
2 - Intake connection flange
❑ With exhaust gas recir‐
culation valve.
3 - Sealing ring
❑ Replace.
4 - 10 Nm
5 - From the intercooler
6 - Intake manifold valve motor
-V157-
7 - 10 Nm
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
108 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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1.5 Injectors - repair
♦ Follow cleanliness rules ⇒ page 88 .
♦ Always replace retainers and 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 - Heat insulation sealing
❑ Replace.
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm +270°
❑ Replace after each re‐
moval.
1.6 Sealing ring for injectors - remove and
install
Special tools and workshop equipment required
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Maintaining the direct injection Diesel system 109
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♦ Assembly sleeve -T10056-
1.6.1 Removal
– Remove carefully old rings from injector.
– Ensure that no burrs are formed on the ring seat in the oper‐
ation above.
1.6.2 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 injector.
– Pull the heat insulation cover with the fastening clip.
– Carefully clean the seating surfaces of the injector ring.
– Slide Assembly sleeve -T10056/1- to stop position on unit in‐
jector.
– Slide upper ring carefully towards assembly sleeve and into
injector seat.
– Remove assembly sleeve.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
110 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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– 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 sleeve.
– Install the heat insulation cover with the fastening clip.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Maintaining the direct injection Diesel system 111
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1.7 Injectors - remove and install
Special tools and workshop
equipment required
♦ Support -VW 387-
♦ Multi-tooth Socket -3410-
♦ Special wrench, long reach
-T10054-
♦ 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 rocker arm
shaft.
– Remove tensioning block securing bolts -3- with Special long
reach wrench, -T10054- , and remove the block.
– Remove injector connector by using a screwdriver. To avoid
inclination, support opposite side of connector with light finger
pressure.
– Check injector locations.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
112 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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– Position the Puller -T10055- into the slot on the injector side
instead of the tensioning block.
– Pull the injector out of cylinder head seat with gentle taps.
1.7.2 Installation
Note
♦
After each repair, the injector requires adjustment, and the
rocker arm set screw and the injector ball head pin need to be
replaced.
♦
The new injectors are supplied 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 manner push the injector into the cylinder head
until it stops.
– Fit the tensioning block into the slot at the injector side.
Note
If the injector is not at a right angle to the tensioning block, the
fastening screw may come loose, thus damaging the injector or
the cylinder head.
– Align the injector as follows.
– Tighten the new securing bolt into the tensioning block until
the injector can still be turned easily.
– Align the injector at a right angle to the camshaft bearing caps.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Maintaining the direct injection Diesel system 113
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– Check the dimension “a” from the external edge of the cylinder
head to the round edge of the injector, using a Vernier caliper
(measurement range at least of 400 mm).
Cylinder Dimension “a”
1 245.0 ± 0.8 mm
2 157.0 ± 0.8 mm
3 65.6 ± 0.8 mm
– Align the injector and tighten the securing bolt to: 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. Roller side -arrow A- positioned
at the highest point of dial gauge -arrow B- positioned at the
lowest point.
– Remove dial gauge.
– Turn set screw inwards into rocker arm until a firm resistance
is noted (injector positioned at stop).
– Turn set screw 225° back off stop.
– Hold set screw in this position and tighten the self-locking nut
to 30 Nm.
– Fit injector connector and install cylinder head cover and tim‐
ing belt guard.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
114 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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2 Engine command unit
2.1 Engine command unit - remove and in‐
stall
– Before removing engine command unit, refer 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 encode the new command unit
⇒ page 116 .
2.2 Querying and erasing fault memory of
the engine command unit
Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis cable (5 m)
-VAS 5051/3-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Engine command unit 115
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Work sequence
– Connect the Vehicle Diagnosis, Measurement and Information
System -VAS 5051A/52- , as follows:
– Connect Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis
cable (5 m) -VAS 5051/3- to the diagnosis connection.
– Start the engine and run it at idle speed.
Only when engine does not run:
– Switch ignition on.
Select operation mode
– Press on the Vehicle self-diagnosis .
Select vehicle system
– Press 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 memory on the display.
– Press 06 End the test function key.
2.3 Adjusting functions and components
Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis cable (5 m)
-VAS 5051/3-
Select, in the Diagnosis, Measurement and Information System -
VAS 5051A/52- the “Assisted fault finding”.
After querying all the command units:
– Press Skip key.
– Select Function/component selection .
– Select Activation .
– Select engine identification codes .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
116 Rep. Gr.23 - Supply system - mechanical injection (diesel)
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– 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 117
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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 evenly distributed on the supports.
♦
Always replace self-locking nuts.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
118 Rep. Gr.26 - Exhaust system
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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 damaged.
10 - 25 Nm
11 - Rear silencer
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Exhaust system components - remove and install 119
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2 Exhaust gas recirculation system
Note
♦
The control of the exhaust gas recirculation system is carried
out by the Direct injection diesel system control unit -J248- via
the Exhaust gas recirculation (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 flange
4 - Exhaust gas recirculation
valve -N18-
❑ Integral part of intake
flange
❑ Can only be replaced to‐
gether with the intake
flange.
5 - Intake manifold valve motor
-V157-
6 - 10 Nm
7 - From the intercooler
8 - Exhaust manifold
9 - Gasket
❑ Replace.
10 - Radiator
❑ For exhaust gas recircu‐
lation.
11 - 25 Nm
12 - For heat exchanger
13 - 25 Nm
14 - 25 Nm
15 - From engine head
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
120 Rep. Gr.26 - Exhaust system
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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 gas recirculation valve.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2. Exhaust gas recirculation system 121
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.
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 Fuse 6 (30) the fuse-holder -S178- of the
battery OK.
Test sequence
– Remove the connector of the coolant temperature sensor.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
122 Rep. Gr.28 - Chamber pre-heating system
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Note
When removing the sensor, the “cold” engine condition is simu‐
lated, and when switching the 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
Special tools and workshop equipment required
♦ Auxiliary measuring cable set -VAG 1594C-
♦ Spanner -3320-
♦ Test probe -VAG 1527B-
Test conditions
• Battery voltage at least 11.5 V
• Ignition switched off.
Test sequence
– Remove heating plug connectors.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Chamber pre-heating system - check 123
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– 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 with Spanner -3320- . Tight‐
ening torque: 15 Nm.
02.09
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
124 Rep. Gr.28 - Chamber pre-heating system
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En otros idiomas
- English: Volkswagen FOX 2004
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