3 - Cyl. Diesel Engine PDF

Service
Workshop Manual
Fox 2004 ➤
3 - Cyl. diesel engine
Engine ID BNM
Edition 02.2009
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Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
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00 - Technical data y Vo lk s es n
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10 - Cylinders,hoengine
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13 - Crankshaft,
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15 - Cylinder head, valve control mechanism

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17 - Lubrication system
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19 - Cooling system
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20 - Supply system - Fuel tank, fuel pump
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21 - Overcharge - turbo
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23 - Supply system - mechanical injection (diesel)
26 - Exhaust system
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28 - Chamber pre-heating system
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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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R007720

Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
Contents
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00 - Technical data . . . d. b.y V. . . . . . . . . . . . . . . . . . . . o.t g.ua.r . . . . . . . . . . . . . . . . . . ...... 1
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1 Technical data ris
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1.1 Engine number
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1.2 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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10 - Cylinders, engine block, support, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1 Engine - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.1 Removal - indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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1.2 Engine - fix on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
spec
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1.3 Notes regarding installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.4 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Supports for the power drive group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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1.6 Additional removal information and instructions for vehicles with air conditioning . . . . . . . . 8
13 - Crankshaft, pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 Engine - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.1 Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2 Crankshaft flanges and flywheel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2.1 Crankshaft oil seal, pulley side - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.2 Crankshaft seal flange - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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3 Counterbalance shaft and retaining frame - remove and install . . . . . . . . . . . . . . . . . . . . . . 23
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3.1 Counterbalance shaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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4 Crankshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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4.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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5 Pistons and connecting rods - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
Contents i
Fox 2004 ➤
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 . . . . . . . . . .n.A.G.. V. o.lk.s.w.ag. e.n.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.3 Safety measures for working Vol
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1.4 Cleanliness rules ise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . a. ra. n. . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Fuel tank - remove ut
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1.6 Fuel pump - sremove
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1.7 Fuel meter sensor - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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1.8 Fuel pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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1.9 Accelerator mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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1.10 Auxiliary pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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1.11 Auxiliary pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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21 - Overcharge - turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1 Overcharge system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1.2 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Turbocharger - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1.4 Intake air cooling system (intercooler) components - remove and install . . . . . . . . . . . . . . 104
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23 - Supply system - mechanical injection (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1 Maintaining the direct injection Diesel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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1.1 Installation locations - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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1.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.3 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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1.4 Intake manifold valve - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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1.5 Injectors - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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1.6 Sealing ring for injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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1.7 Injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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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
ii Contents
Fox 2004 ➤
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.
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Cylinder volume l 1,4

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Power kW / rpm 51/4000

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Torque Nm / rpm 155/1600 to 2800 ab

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Bore ∅Ø mm 79,5 wit

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Stroke mm 95,5
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Compression rate 19,5

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Octanage at least 49
Firing order 1-2-3
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Catalytic converter yes

Recirculation of exhaust gases yes
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Charged yes
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Intercooler yes
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1. Technical data 1
Fox 2004 ➤
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-
port -VW 313-
port -VW 540-
♦ Workshop winch -
V.A.G 1202 A-
♦ Oil sump -V.A.G 1306-
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2 Rep. Gr.10 - Cylinders, engine block, support, cover

Fox 2004 ➤
♦ 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-
port -3147-
♦ 3 Washers A13 X 24 X 2.5 n AG. Volkswagen AG do
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♦ 2 Washers A10.5 X 21 X2 d byV
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♦ Support bracket -10-222A- with Rack -10-222A/1-

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♦ Adapter -10-222A/18-
1. Engine - remove and install 3

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3 - Cyl. diesel engine - Edition 02.2009 d byV
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Modifying Engine bracket -T10012- aut or
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– If the modification has not yet been carried out, drill an addi‐
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1.1 Removal - indications
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Check whether vehicle has code radio, if so obtain the anti-theft
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– The engine is removed downwards, along with transmission.

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WARNING
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For installation jobs, especially in the engine compartment, due
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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 ➤
– 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. olks
wage es n
o
yV t gu
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– Install the Support bracket -10-222A- and support engine and
erm
ab
gearbox as shown in diagram.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove engine support -1- and engine console -2-.

m
at
om
– Disconnect right-hand drive shaft⇒ Rep. Gr. 40 . ion

c
in t
or
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e
– Loosen front exhaust pipe from turbocharger. Loosen double

at
do
riv
clamp and push exhaust pipe backwards ⇒ page 118 .

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– 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 ➤
– 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.
gen AG
. Volkswagen AG
d a oes
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Place two A 10.5 X 21 X 2 Washers between engine bracket and
ce
le
un
pt
compact bracket so that the engine bracket lies flat on the com‐
an
d
itte
pact bracket.
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ility
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– Remove securing bolts from the bottom of engine/gearbox.
wit
, is n
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– Lift engine and gearbox lightly using the Gearbox or Engine +
hole
spec
gearbox combo jack -VAG 1383A-
es, in part or in w
t to the co
– Remove the spindle of the Support bracket -10-222A- on the
engine side.
rrectness of i
Note
l purpos
Use Stepladder -VAS 5058- to remove the spindle.
nform
mercia
– Separate engine from gearbox by carefully lowering it and us‐
a
com
tio
ing the Gearbox or Engine + gearbox combo jack -VAG
n in
r
1383A;- remove it from below.

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Note
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t.
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When lowering, handle the engine carefully to prevent damaging
t. rig
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the body. cop Vo
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Prote AG.
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 ➤
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 facewatoward

gen AG the
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pulley. yV
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♦ Drilled holes on supports are countedthofrom the hook.
ris nte
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– Fasten the engine with the Support -VW 540- on the Stand -
ce
le
un
pt
VW 313- .
an
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itte
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erm
ab
1.3 Notes regarding installation
ility
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Installation is carried out by reversing the removal sequence,
ole,
considering the following:
spec
t to the co
– 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.
rrectne
– Check if guides for fastening engine and transmission are
placed on the engine block and, if necessary, install them.
ss o
cial p
f
– Align engine, moving it slightly so that the supports are seated
inform
without stress.
mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
r
Assembly support tightening torques ⇒ page 8 .

p
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en
ng
t.
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op
– Electrical conections and installation ⇒ Rep. Gr. 97 : C py
ht. rig
rig ht
– Remove Locking pin -T10060- -arrow- and replace securing
py by
co Vo
by lksw
bolt. Prote
cted AG.
agen
– 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 ➤
1.4 Tightening torque

Location Tightening tor‐
que
Screws, nuts M6 10 Nm
M8 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°.
AG. Volkswagen AG d
3- 45 Nm. agen oes
olksw not
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ara
1) Replace. ised
nte
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ility
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1.6 Additional removal information and in‐

h re
hole
spec
structions for vehicles with air condition‐

es, in part or in w
ing
t to the co
rrectness of i
Note
l purpos
♦ The air conditioning cooling gas circuit must be opened in or‐

der to remove the engine.
nf
ercia
♦ To prevent damages to condenser and cooling gas hoses, do

rm
m
atio
not fold, twist or overstretch the hoses.

om
n in
or c
thi
– Remove air conditioning compressor and anchor it to the body.

te
sd
iva
⇒ Rep. Gr. 87 .
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– Purge the cooling gas from air conditioning circuit and open
en
ng
t.
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the gas circuit ⇒ Rep. Gr. 87 .
Co
Cop py
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rig ht
py by
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by lksw
Note cted agen
Prote AG.
The air conditioning compressor may remain fitted in its place.

Fox 2004 ➤
13 – Crankshaft, pistons
1 Engine - dismantle and assemble
AG. Volkswagen AG d
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
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Note
c by lksw
cted agen
Prote AG.
♦ 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

torque
1. Engine - dismantle and assemble 9

Fox 2004 ➤
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 n AG. Volkswagen AG do
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loosen or tighten. olks es n
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❑ To remove, use Extrac‐ ir se
d ran
tee
tor -T10052- . autho
or
ac
❑ Remove and install ss
ce
le
⇒ page 58 .
un
pt
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9 - 10 Nm
erm
ab
ility
ot p
10 - Mechanical distribution
wit
is n
rear cover
h re
ole,
11 - Sealing ring
spec
❑ Replace if damaged.
t to the co
12 - Pulley
rrectne
13 - Water pump
❑ Remove and install ⇒ page 80 .
ss
14 - Crankshaft gear
o
cial p
f inform
15 - 120 Nm + 90°
mer
❑ Replace after each removal..

atio
om
❑ Immobilise with Lock -3415- to loosen or tighten.

c
i
or
n thi
e
❑ Do not apply additional oil or grease to the threads and recess/flanges.

t
sd
iva
o
pr
❑ The angular torque can be performed in several stages.

um
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t.
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Prote AG.
10 Rep. Gr.13 - Crankshaft, pistons

Fox 2004 ➤
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 AG. Volkswagen AG d
tightening torque. lkswagen oes
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4 - Pressure regulating
ris
ed valve
b ran
tee
o
❑ To crankcase
au
th
vent. or
ac
ss
5 - Cover
ce
le
un
pt
an
❑ Replace seal if dam‐

d
itte
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aged.
rm
ab
pe
ility
6 - Gasket
ot
wit
, is n
h re
hole
spec
7 - Oil filling nozzle

es, in part or in w
t to the co
❑ Replace.
8 - Engine and gearbox sup‐
port
rrectness of i
❑ With fuel tube.

l purpos
9 - Cylinder head cover gasket

nform
ercia
m
10 - 20 Nm
a
com
tion in
11 - Lifting eye
r
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12 - 10 Nm
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13 - Central connector
en
ng
t.
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❑ To injector t. Cop py
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14 - From servo brake p by
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by c lksw
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Prote AG.

Fox 2004 ➤
15 - Tandem pump
❑ For supplying fuel and vacuum.
❑ Check ⇒ page 95 .
16 - 25 Nm
17 - Supply hose gen AG
. Volkswagen AG
swa does
❑ From fuel filter ⇒ Item 1 (page yV
olk 87) . not
gu
d b ara
❑ White or with white marking.
orise nte
eo
h
ut
❑ Check that it is securely
ss a installed. ra
c
❑ Fasten with spring braces.
ce
le
un
pt
an
d
itte
18 - Return hose
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ab
❑ To fuel filter ⇒ Item 1 (page 87) .
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ility
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wit
❑ Blue or blue marked.
, is n
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❑ Check that it is securely installed.
hole
spec
es, in part or in w
t to the co
19 - Gasket
❑ Replace.
rrectness of i
20 - Pin 10 Nm
l purpos
❑ To engine cover.
21 - Engine and gearbox support
nform
ercia
22 - Hexagonal nut
m
a
com
23 - Cylinder head gasket tion in

r
te o
thi
❑ Replace.
s
iva
do
❑ Observe identification ⇒ page 35 .

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rp
cum
fo
❑ When replacing, use completely new coolant.

en
ng
t.
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op py
24 - Hall Sensor -G40-
. C rig
ht ht
rig by
❑ To the camshaft position. copy Vo
by lksw
cted agen
❑ Loosen to remove sealing ring from the mechanical distribution rear cover.
Prote AG.
25 - Cylinder head securing bolt

❑ Replace.
❑ Follow the installation and removal sequence ⇒ page 46 .
❑ Insert washers into cylinder head before installing.
26 - Injectors
Part III
WARNING

torque

Fox 2004 ➤
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‐ AG. Volkswagen AG d
port agen oes
olksw not
V gu
❑ To the Sensor Hall - d by ara
ise nte
G40- connector of the ut
hor eo
camshaft position and ss a ra
c
Engine speed sensor -
ce
le
un
G28- .
pt
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d
itte
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8 - 10 Nm
erm
ab
ility
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9 - Gasket
wit
is n
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❑ Replace.
ole,
spec
10 - Oil filter bracket
t to the co
semble ⇒ page 64 .
rrectne
11 - 15 Nm + 90°
❑ Replace after each re‐
s
moval.
s o
cial p
f
❑ First, install upper left and lower right bolts, then tighten the four bolts diagonally.
inform
mer
12 - Sealing ring
atio
m
❑ Replace.
o
n
c
i
or
n thi
13 - 20 Nm
te
sd
iva
o
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14 - Engine speed sensor -G28-

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ng
15 - Connection
t.
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Cop py
❑ To temperature sensor.
t. rig
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pyri by
Vo
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16 - 15 Nm by c lksw
cted agen
Prote AG.
17 - Coolant temperature sensor
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 ➤
AG. Volkswagen AG d
agen oes
lksw not
21 - 25 Nm d by
Vo gu
ara
ise nte
r
22 - Oil crankcase ut
ho eo
ra
a
❑ Clean sealing surface before installation. ss c
ce
le
un
❑ Install with Silicone sealant -D 176 404 A2 - ⇒ page 68
pt
an
d
itte
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❑ To remove crankcase, first remove the transmission ⇒ Rep. Gr. 34 .
rm
ab
pe
ility
23 - 15 Nm
ot
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❑ To remove the rear bolts close to the transmission, it first must be removed⇒ Rep. Gr. 34 .
h re
hole
spec
24 - Cover
es, in part or in w
t to the co
❑ With sealing tape.
❑ Clean filter if dirty.
rrectness of i
25 - Mounting frame
❑ Before installing, check whether the fixing guides for centralizing on the engine block are in their place,
l purpos
and that the fuel distribution ring is inserted in the mounting frame.
nform
ercia
26 - 40 Nm
m
a
com
tio
27 - Protective cover
n in
r
te o
thi
❑ To drive shaft.
s
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fo
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ng
t.
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1.1 Poly-V belt - remove and install
Co
Cop py
t. rig
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Special tools and workshop equipment required p by
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by c lksw
cted agen
♦ Retaining pin -T10060 A- Prote AG.
♦ 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 ➤
– Turn tensioning element in arrow direction to relieve tension

on Poly-V belt.
– Lock tensioning element with Retaining pin -T10060A- .

– Remove Poly-V belt.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
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ab
1.1.2 Installation
pe
ility
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wit
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– The installation is carried out by inverting the removal se‐
h re
hole
quence.
spec
es, in part or in w
Note t to the co
rrectness of i
♦ Make sure before installing Poly-V belt that all the ancillaries
(alternator, air conditioning compressor) are tightlysecured .
l purpos
♦ When fitting Poly-V belt, observe the direction in which it func‐

tions and check it is seated correctly on the pulley.
nform
ercia
♦ In vehicles without air conditioning, installation of Poly-V belt

m
on the alternador must be the last step.

com
tion in
r
♦ In vehicles with air conditioning, installation of Poly-V belt last

te o
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s
on the air conditioning compressor.

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When the job is finished, always:

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– Start the engine and check belt movement. ht. rig
rig ht
py by
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Belt path for vehicles without air conditioning. by c lksw
cted agen
Prote AG.

Fox 2004 ➤
Belt path for vehicles with air conditioning.
AG. Volkswagen AG d
agen oes
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ce
le
un
pt
an
d
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pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
2 Crankshaft flanges and flywheel - re‐

move and install
Note
Clutch repairs: ⇒ Rep. Gr. 30 .
WARNING

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 AG. Volkswagen AG d
agen oes
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❑ Must be positioned
by Vol on not
gu
the fixingrise guides.
d ara
nte
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❑ Removeaut and install ra
c
⇒s page 20 .
s
ce
le
un
❑ Install with Silicone seal

pt
an
d
itte
-D176404 A2-
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ab
⇒ page 20 .
pe
ility
ot
3 - Engine block
wit
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❑ Removing and installing

hole
spec
crankshaft ⇒ page 29
es, in part or in w
t to the co

semble pistons and con‐
necting rods
⇒ page 32
rrectness of i
4 - Engine flywheel
l purpos
❑ To remove and install

the flywheel, immobilise
nform
ercia
with the Flywheel lock

-3386-
m
a
com
tion in
5 - 60 Nm + 90°
r
te o
thi

s
iva
do
moval.
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cum
fo
en
g
6 - Intermediate plate
n
t.
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op py
❑ Must be positioned on fixing guides.
t. C rig
gh ht
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❑ Do not damage / bend during assembly
cop Vo
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cted agen
Prote
7 - 15 Nm
AG.
8 - Sealing flange with seal

❑ Complete replacement only.
2. Crankshaft flanges and flywheel - remove and install 17

Fox 2004 ➤
❑ 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

equipment required
♦ Extractor -3203-
♦ Lock -3415-
♦ Assembly sleeve -T10053-
(enc. 1/2") -VAG 1331-
Nm (enc. 1/2") -VAG 1332-
lkswage es n
o ot g
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d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
2.1.1 Removal
thi
te
sd
iva
o
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cu

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m
f
en
ng
t.
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– Remove timing belt ⇒ page 41 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
– Remove crankshaft gear. To do this, immobilise gear with the

Lock -3415- .
– To guide the seal Extractor -3203- , install the gear fasteningen AG. Volkswagen AG
screw manually up to the crankshaft stop. olks
wag does
no
V t gu
by ara
– Give the inside part of the Extractor -3203- two turns
ris
ed (approx. nte
3 mm) from the external side, and lock with theau
thoslotted bolt. eo
ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
– Lubricate the threaded head of the oil seal Extractor, -3203-
spec
es, in part or in w
install and screw as firmly as possible onto the seal.
t to the co
– Loosen the slotted screw and turn the inner part against the
crankshaft until the seal is extracted.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
2.1.2 Installation
r
rp
cu
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f
en
ng
t.
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Cop py
. rig
Note
ht ht
rig by
copy Vo
by lksw
cted
Do not apply additional lubricant or grease to the sealing lip of the
agen
Prote AG.
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 ➤
– 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

equipment required
♦ Lock -3415-
(enc. 1/2") -VAG 1331-
Nm (enc. 1/2") -VAG 1332-
♦ Hand drill plastic brush
♦ Silicone seal -D176404 A2-
♦ Flat spatula
AG. Volkswagen AG d
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ility
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nf
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m
atio
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2.2.1 Removal
o
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Prote AG.

Fox 2004 ➤
– 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‐
agen
AG. Volkswagen AG d
plying the sealant. o
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tho or
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pt
du
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itte
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ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

Fox 2004 ➤
– 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 .
AG. Volkswagen AG d
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Note by
Vol not
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After installation, the sealant should dry for approx. 30 minutes
aut
h
ra
before replenishing the engine with oil. ss c
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nl
pt
du
an
Install timing belt and adjust distribution times ⇒ page 41 .
itte
y li
erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Prote AG.

Fox 2004 ➤
3 Counterbalance shaft and retaining

frame - remove and install
Note
All bearing and running surfaces must be lubricated before as‐

sembly.
AG. Volkswagen AG d
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WARNING ed by gu
ara
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ut
Always replace
ss a self-locking nuts and screws subject to angular ra
c
torque
ce
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un
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1 - Chain
ot
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❑ Observe fastening posi‐
hole
tion ⇒ page 25 .
spec
es, in part or in w
t to the co
2 - 100 Nm +90°
moval.
rrectness of i
❑ The angular torque
could be undertaken in
l purpos
several stages.
❑ To loose and tighten,
nform
ercia
use Multi-point spanner

m
-T10061- .
a
com
tion in
3 - Counterbalance
r
te o
thi
❑ It can be installed in one

s
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do
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position only. The holes

rp
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are displaced.
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op
4 - Gear C py
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❑ For counterbalance p by
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shaft.
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are displaced.
5 - Fastening sleeve
6 - 20 Nm + 90°
moval.
7 - Gear
❑ For oil pump.
are displaced.
8 - Cover
❑ Clean strainer if soiled.
9 - 5 Nm
10 - Sealing ring
❑ Replace.
3. Counterbalance shaft and retaining frame - remove and install 23

Fox 2004 ➤
❑ 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
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.
15 - Sealing ring
❑ Replace.
❑ Check that it is firmly seated on the mounting frame. agen
AG. Volkswagen AG d
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16 - Engine block d by V gu
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17 - Gear autho eo
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18 - 20 Nm
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19 - Chain tensioning element with tensioning plate.
itte
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❑ To remove, immobilise with Locking pin -T10060- .
ility
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20 - 8 Nm + 90°
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
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Prote AG.

Fox 2004 ➤
3.1 Counterbalance shaft - remove and install

equipment required
♦ Pin -T10060-
♦ Multi-point spanner -
T10061-
(enc. 1/2") -VAG 1331-
wage es n
♦ Torque wrench - 40 to 200 yV
olks ot g
ua
Nm (enc. 1/2") -VAG 1332- ise d b ran
r tee
ho
♦ Spanner (24/27 mm AF)s aut or
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s
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pt
du
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ab
ility
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es, in part or in w
t to the co
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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Cop py
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Prote AG.
3.1.1 Removal
– Remove crankcase ⇒ page 68 .
– Remove sealing flange, pulley side ⇒ page 17 .
– Remove cover securing bolts.
– Remove cover from mounting frame.

Fox 2004 ➤
– 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.
. Volkswagen AG
a gen AG does
– Remove the chain and put it on a clean
Vol surface.
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– Immobilise counterbalance shaft, as shown, with a Spanner
pe
ility
ot
(24/27 mm AF) -1-.
wit
, is n
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hole
spec
Note
es, in part or in w
t to the co
When immobilizing the counterbalance shaft, make sure that the
spanner is centred on the counterbalance and at right angles to
rrectness of i
counterbalance shaft.
l purpos
– Loosen fastening bolt -2- of the counterbalance.
nform
ercia
Note
m
a
com
tion in
r
Only loosen the fastening bolt -2- of the counterbalance; do not

te o
thi
remove.
s
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– Unbolt mounting frame --3-- from engine block and remove it

n
t.
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with counterbalance shaft. ht. Cop py
rig
rig ht
– Put the mounting frame on a clean surface. py by
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– Remove counterbalance securing bolts. Prote AG.
– 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 ➤
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.
olkswagen AG
en AG. V
– Bolt mounting frame witholkcounterbalance
swa
g
shaft todoengine
es n
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block. Tightening torque:
ed by V
20 Nm. ua
ra
ris nte
tho
– Check that mounting frame aligns flush with outer edge of en‐e or a
au
gine block ons the pulley end.
s c
ce
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nl
pt
– Immobilise counterbalance shaft, as shown, with a Spanner
du
an
itte
(24/27 mm AF) -1-.
y li
erm
ab
ility
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wit
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Note
h re
hole
spec
When immobilizing the counterbalance shaft, make sure that the
es, in part or in w
spanner is centred on the counterbalance and at right angles to
t to the co
counterbalance shaft.
rrectness of i
– Tighten fastening bolt -2- of the counterbalance. Tightening
torque: 100 Nm +90°.
l purpos
nform
Note
mercia
at
The fastening bolt is a tensioning bolt and must always be re‐
om
ion
placed.
c
in t
or
his
ate
do
riv
– Install chain tensioning element. Tightening torque: 8 Nm +

p
cum
or
90°.
f
en
ng
t.
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Cop py
t. rig
gh ht
Note yri
p by
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Prote
The fastening bolts of the chain tensioning element are tensioning
AG.
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 ➤
– 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.

. Volkswagen AG
gen AG does
swa
– Fit the free sprocket in the chain and tighten the free bsprocket
yV
olk not
gu
to the mounting frame. Tightening torque: 20 Nm.rise d ara
nte
tho eo
– Remove Locking pin -T10060- from chain tensioning
s au element. ra
c
s
ce
e
nl
pt
– Make sure that the marks on the crankshaft sprocket and
du
an
itte
counterbalance shaft sprocket align with the colour-coded
y li
erm
ab
chain links -arrows-.
ility
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Note
hole
spec
es, in part or in w
t to the co
The colour-coded chain links are marked with a notch.
– Install pulley end sealing flange ⇒ page 17 .
rrectness of i
– Install counterbalance shaft cover. Tightening torque: 5 Nm.
l purpos
Note
nform
mercia
at
♦ Before installing cover, lubricate O-ring of oil pump, as well as
om
ion
shaft on inside of cover
c
in t
or
his
te
♦ Make sure of the proper seating of sealing strip in cover.

a
do
priv
cum
or
♦ When installing cover, ensure that cover engages in mounting

f
en
g
frame.
n
t.
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Cop py
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– Install crankcase ⇒ page 68 . p by
co Vo
by lksw
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– Install and adjust timing belt ⇒ page 41 . Prote AG.

AG. Volkswagen AG d
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agen oes
not
Fox 2004 ➤
ol
byV gu 3 - Cyl. diesel engine - Edition 02.2009
d ara
ise nte
or eo
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aut ra
4 Crankshaft - remove and install
ss c
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Note
ility
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♦ Before removing crankshaft, make sure that a proper surface
h re
has been prepared to ensure that the speed sensor rotor is not
hole
spec
damaged, or does not touch another item.
es, in part or in w
t to the co
assembly.
rrectness of i
l purpos
WARNING
nform
ercia
torque
m
at
om
ion
c
in t
or
his
ate
1 - Bearing shells 1, 2 and 4
do
priv
cum
or
❑ For bearing shells with‐

f
en
ng
out oil groove.

t.
yi Co
Cop py
❑ For engine block with oil ht. rig
rig ht
groove. py by
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by lksw
cted
❑ Do not interchange
agen
Prote AG.
used bearing shells
(mark)
2 - 65 Nm + 90°
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 sensor rotor
each time bolts are loos‐
ened
❑ Remove and install.
⇒ page 30
6 - 10 Nm + 90°
7 - Fitted pin
❑ Check the projection from crankshaft ⇒ page 30
4. Crankshaft - remove and install 29

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Fox 2004 hor➤
is
eo
ut
3 - Cyl.
ss a diesel engine - Edition 02.2009 ra
c
ce
le
un
pt
8 - Crankshaft
an
d
itte
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❑ See notes before removing ⇒ page 29 .
rm
ab
pe
ility
❑ Axial clearance new: 0.07...0.17 mm. Wear limit: 0.37 mm.
ot
wit
, is n
❑ Check radial clearance with Plastigage. New: 0.03...00.08 mm. Wear limit: 0.17 mm.
h re
hole
❑ Do not rotate crankshaft while measuring radial clearance.
spec
es, in part or in w
❑ Crankshaft dimensions ⇒ page 30 .
t to the co
9 - Stop ring
❑ To engine block, bearing 3.
rrectness of i
l purpos
Check fitted pin projection out of crankshaft
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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Prote AG.
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‐ Crankshaft trunnion Connecting rod
ishing -∅ pin-∅
Basic dimension -0,022 -0,022
54,00 47,80
-0,042 -0,042
First rework -0,022 -0,022
53,75 47,55
-0,042 -0,042

Fox 2004 ➤
Dimension for fin‐ Crankshaft trunnion Connecting rod

ishing -∅ pin-∅
Second rework -0,022 -0,022
53,50 47,30
-0,042 -0,042
Third rework -0,022 -0,022
53,25 47,05
-0,042 -0,042
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted
31
agen
Prote AG.
4. Crankshaft - remove and install
Fox 2004 ➤
5 Pistons and connecting rods - dis‐

mantle and assemble
Note
All bearing and running surfaces must be lubricated before as‐

sembly.
WARNING

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 AG. Volkswagen AG d
cylinder ⇒ page 34 agen oes
olksw not
V gu
❑ The arrow on the piston ed by ara
nte
is
head should be pointed hor eo
in the direction of the aut ra
ss c
pulley.
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nl
pt
du
❑ Install by using a piston

an
itte
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ring compressing tool.

erm
ab
❑ Replace piston in case

ility
ot p
of cracks on its skirt.

wit
, is n
h re
❑ Check the piston projec‐

hole
spec
tion at TDC
es, in part or in w
⇒ page 34
t to the co
3 - Piston pin
❑ In case of difficulties in
rrectness of i
the removal, heat the

piston to 60 °C.
l purpos
❑ Remove and install with

Puller and fitter -VW 222
nf
ercia
A- .
rm
m
atio
m
4 - Piston pin retaining ring

o
n in
or c
5 - Connection rod
thi
te
sd
iva
❑ Only replace as a set.

o
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rp
cu
o
❑ Mark correspondence with cylinder -A-.

f
en
ng
t.
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❑ Mounting position: Marks -B- shall point towards the pulley. t. Cop py
rig
gh ht
pyri by
Vo
o
32
by c lksw
cted
Rep. Gr.13 - Crankshaft, pistons
agen
Prote AG.
Fox 2004 ➤
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.
❑ 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
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°
❑ Lubricate threads and contact surface. AG. Volkswagen AG d
agen oes
olksw not
❑ First tighten evenly to 5 Nm.ed by V gu
ara
is nte
❑ To measure radial clearance,
ut
hor
use old bolts. eo
a ra
ss c
ce
e
nl
pt
du
an
Check piston ring gap

itte
y li
erm
ab
– Push ring firmly from above down to approx. 15 mm from bot‐

ility
ot p
tom end of cylinder.

wit
, is n
h re
Piston ring New Wear limit

hole
spec
Dimensions in mm
es, in part or in w
t to the co
1. compression ring 0,25...0,40 1,0

rrectness of i
Oil scraper ring 0,25...0,50 1,0

l purpos
nform
ercia
Checking ring to groove clearance

m
at
Clean groove before check.

om
ion
c
in t
or
Piston ring New Wear limit

his
ate
Dimensions in mm
do
priv
cum
or

f
en
ng
t.
yi Co
2. compression ring 0,05...0,08
t. Cop
0,25 py
rig
gh
Oil scraper ring 0,03...0,06 0,15
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Pistons and connecting rods - dismantle and assemble 33

Fox 2004 ➤
Check cylinder diameters

♦ 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 agen
AG. Volkswagen AG d
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b
The cylinder diameter cannot be measured while the engine block rise
d ara
nte
is secured to the assembly stand with the Engine and gearboxutho eo
ra
support -VW 540- , for in this case inaccurate measurements
ss a
are c
possible.
ce
le
un
pt
an
d
itte
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Installation position and correspondence to respective cylinder
rm
ab
pe
ility
Piston in cylinders 1 and 2.
ot
wit
, is n
h re
Larger intake valve chamber towards the flywheel -arrows-.
hole
spec
Piston in cylinder 3.
es, in part or in w
t to the co
Larger intake valve chamber towards the pulley -arrow-.
rrectness of i
Note
l purpos
♦ The new correspondence between pistons and cylinders is in‐

dicated by color marking on the piston head.
nform
ercia
♦ Piston for cylinders 1 and 2: marking 1/2.

m
a
com
tion in
♦ Piston for cylinder 3: marking 3.

r
te o
thi
s
iva
do
Check the piston projection at TDC

r
rp
cum
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
♦ Measurement tool -VW 382/7-
♦ Universal measurement tool -VW 385/17-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
Test sequence
ss c
ce
le
un
pt
– The piston projection at TDC must be measured when instal‐

an
d
itte
ling the new pistons. Depending on the piston projections,

y li
erm
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install the corresponding head gasket, in compliance with the

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Turn the engine clockwise to check the piston projections in TDC.

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Piston projection Identification

Holes/grooves
ss
0.91 mm...1.00 mm 1
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1.01 mm...10.10 mm 2
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1.11 mm...10.20 mm 3
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Identification of cylinder head gasket

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Note
If different figures are obtained when measuring piston projection,

the highest figure should be taken when selecting the head gas‐
ket.
5. Pistons and connecting rods - dismantle and assemble 35

Fox 2004 ➤
5.1 Piston and cylinder dimensions

Dimension for fin‐ ∅ Piston ∅ cilinder
ishing
Basic dimension mm 79,47 79,51
1. rework mm 79,97 80,01
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Fox 2004 ➤
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15 – Cylinder head, valve control mechanism
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1 Cylinder head - remove and install
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Check compression ⇒ page 49 .
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♦ When mounting a replacement head with the camshaft moun‐
t to the co
ted, lubricate all the contact surfaces between tappets and
cams before installing the head cover.
rrectness of i
assembly.
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♦ The plastic shims provided for protecting the open valves

should not be removed until immediately before fitting cylinder
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head.
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♦ When replacing head, the cooling liquid should be totally re‐
com
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placed too.
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1. Cylinder head - remove and install 37

Fox 2004 ➤
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❑ Check wear.
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❑ Do not bend.
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❑ Remove, install, and ad‐
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3 - 10 Nm
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4 - 25 Nm
5 - 100 Nm
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6 - Camshaft gear
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7 - Pulley
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❑ With engine phase sen‐

sor wheel.
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❑ Use Counter-hold tool -
on in
T10051- to loosen and
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tighten.
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9 - Sealing ring
10 - Hall Sensor -G40-
❑ To the camshaft posi‐
tion.
❑ To remove, remove
sealing ring.
❑ 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.
38 Rep. Gr.15 - Cylinder head, valve control mechanism

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17 - Oil filling nozzle ss
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❑ Replace.
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18 - Cover
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❑ Replace seal if damaged.
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19 - Gasket
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20 - Support
❑ With fuel tube/hose.
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21 - Cylinder head cover gasket
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22 - 20 Nm
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23 - Lifting eye
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24 - Injection unit
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25 - Central connector
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❑ To injector.
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26 - From servo brake
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27 - Tandem pump
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❑ For supplying fuel and vacuum.
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28 - Supply hose
❑ From fuel filter ⇒ Item 1 (page 87) .
❑ White or with white marking.
29 - Return hose
30 - Gasket
❑ Replace.
31 - Support
32 - Hexagonal nut
33 - Cylinder head
❑ 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 ➤
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 AG. Volkswagen A

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♦ Part number = -arrow 1-.by Volk ot g
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ing on the piston projection. When replacing the cylinder head

hole
spec
gasket, install a new part with the same identification.

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Fox 2004 ➤
1.1 Timing belt - remove and install, adjust

equipment required
♦ Diesel injection pump lock‐
ing pin -3359-
♦ Pin wrench -3387-
♦ Crankshaft stop -T10050-
♦ Fitter -T10015-
(enc. 1/2") -VAG 1331-
Nm (enc. 1/2") -VAG 1332-
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♦ Support bracket -10-222A- with Rack -10-222 A/1-

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Fox 2004 ut ➤
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1.1.1 Removal
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Note
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Adjustment work on timing belts should only be carried out on cold
t to the co
engines, as the indicator on the tensioning element changes de‐
pending on the engine temperature.
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– Remove the engine cover.
– Remove the hose between intercooler and intake connecting
ss
flange.
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– Fit Support bracket -10-222 A- as shown and support the en‐
form
mer
gine in its installation position.
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– Remove engine support -1- and engine console -2-.

– Remove Locking pin -T10060- from tensioning element.
– Remove mechanical distribution upper cover.
– 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 ➤
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.
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– Lock timing belt gear at crankshaft, using Vol
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wa stop - not
T10050- . To do this, push crankshaft ed by stop from the face side gu
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The marks on the crankshaft gear and the crankshaft stop must
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align. At the same time, the shaft of the crankshaft stop must en‐
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gage into the hole in the sealing flange.
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– Mark timing belt operation direction.
es, in part or in w
t to the co
– Loosen securing nut of the tensioning element.
rrectness of i
– Loosen the fastening bolts of the camshaft gear -1-, until the
gear can be moved into the elongated holes.
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– Turn Pin wrench -3387- counterclockwise (opposite direction
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of arrow) until the timing belt tensioning element can be fixed
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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 ➤
– 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- .
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– Turn crankshaft twice in theagengine
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♦ When doing this, the crankshaft stop end shall engage in the
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sealing flange while turning the engine.

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♦ When the crankshaft is turned beyond the TDC of cylinder 1

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and the crankshaft stop is not engaged in the sealing flange,

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turn the crankshaft 1/4turn in the reverse direction in order to

hole
spec
readjust TDC of cylinder 1. No correction is allowed while the

es, in part or in w
t to the co
engine is turning, so as to ensure the correct operation of the

crankshaft stop.
rrectness of i
– Once the Crankshaft stop -T10050- has engaged, check

whether the gear can be locked by using the Locking pin
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-3359- .
If the hub cannot be locked:
nform
ercia
– Pull the Crankshaft stop -T10050- out of the hole in the sealing
m
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flange and turn the crankshaft until the gear can be locked with
on
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the Locking pin -3359- .

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Rep. Gr.15 - Cylinder head, valve control mechanism Prote AG.
Fox 2004 ➤
– 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.
AG. Volkswagen AG d
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When doing this, utthe crankshaft stop end shall engage in the
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♦ a
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♦ When the crankshaft is turned beyond the TDC of cylinder 1

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turn the crankshaft 1/4turn in the reverse direction in order to

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readjust TDC of cylinder 1. No correction is allowed while the

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engine is turning, so as to ensure the correct operation of the

h re
hole
crankshaft stop.
spec
es, in part or in w
t to the co
– Repeat checking.
– Install the lower cover of the mechanical distribution and the
rrectness of i
vibration absorber.
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– Install mechanical distribution centre cover.

– Install mechanical distribution upper cover.
nform
ercia
– Install engine support and console. Torque setting ⇒ page 8 .

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– Install the hoses between intercooler and turbocharger, and

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between intercooler and intake connecting flange.

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– Install engine noise insulation ⇒ Rep. Gr. 50 .

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Fox 2004 ➤
1.2 Cylinder head - remove and install

equipment required
♦ Support -10-222A-
♦ Support -T10014-
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♦ Torque wrench - 5 to 50 Nm rised b ara
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(enc. 1/2") -VAG 1331- ut
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♦ Torque wrench - 40 to 200 s
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Nm (enc. 1/2") -VAG 1332-
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♦ Vacuum pump -
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V.A.G 1390-
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♦ Fluid receptacle -V.A.G 1390/1-
1.2.1 Removal

AG. Volkswagen AG d
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au ra
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Note du
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ility
Since the lifting eyes are located on the cylinder head, an addi‐
ot p
tional support should be fastened to the engine block for removing
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the cylinder head.
hole
spec
es, in part or in w
– Fit Support bracket -10-222A- as shown and support the en‐
t to the co
gine in its installation position.
– Carefully lift the engine slightly with spindle -A-.
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– Attach Retainer -T10014- to engine block using the threaded
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hole in the vicinity of water pump, as illustrated. Tightening Cop py
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– Lift engine slightly using second spindle -B- until spindle -A- is
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relieved.
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– 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 ➤
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:
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1st stage (torque) 40 Nm orise nte
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2nd stage (torque) 60 Nm aut ra
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– 2. Tighten with normal spanner:
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3rd stage (angular torque) 90°
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4th stage (angular torque) 90°
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Note
es, in part or in w
No retightening of the cylinder head is required after repairs. t to the co

rrectness of i
– After tightening the cylinder head, turn the camshaft so that all
the cams in cylinder 1 are turned equally upwards. Before
l purpos
mounting the cylinder head, turn the crankshaft in the engine

rotation direction until TDC ⇒ page 41 .
nform
ercia
– Perform test drive and check fault memory ⇒ page 115 .

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Fox 2004 ➤
1.3 Compression - check

equipment required
♦ U/J extension and socket,
10 mm -3220-
(enc. 1/2") -VAG 1331-
♦ Adapter -V.A.G 1381/12-
♦ Compression meter - lkswage es n
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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 ➤
– 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.
AG. Volkswagen AG d
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Fox 2004 ➤
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
AG. Volkswagen AG d
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Always replace self-locking nuts and screws by subject
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❑ Loosen and tighten in
h re
ole,
the proper order
spec
⇒ page 58
t to the co
2 - Injector drive arm shaft
rrectne
❑ Replace.
❑ Loosen and tighten in
ss
the proper order
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⇒ page 46
nform
mer
❑ Before installing, set
atio
washers in cylinder
om
head. n
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4 - Washer
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❑ For head screws.

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5 - Tappet
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❑ With hydraulic offsetting
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of valve gap.
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❑ 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 .
2. Valve command - repair 51

Fox 2004 ➤
9 - Valve internal spring agen

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❑ Removing and installing: Cylinder head removed: by Vo with Compressor device -2037-
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⇒ page 56 . rise
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❑ Install in the cylinder head before putting
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10 - Valve stem seal
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❑ Replace ⇒ page 56 .
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11 - Valve guide
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12 - Injection unit
spec
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13 - Cylinder head
❑ See note ⇒ page 51 .
rrectne
❑ Rework valve seats ⇒ page 53
s
14 - Oil seal
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❑ Do not apply additional lubricant or grease to the seal lip.
inform
mer
❑ Before installation, remove oil residues from crankshaft trunnion with clean cloth.
atio
m
❑ For installation, cover the groove in the camshaft tapered section with adhesive tape.
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❑ Remove and install.
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15 - Valves
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❑ Valve dimensions ⇒ page 53
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16 - Bearing shell
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❑ Ensure proper seating of retaining clips in bearing caps and cylinder head.
agen
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17 - Camshaft
❑ Check axial clearance ⇒ page 52
❑ 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 ➤

♦ 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 AG. Volkswagen AG d

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♦ Cam base diameter: -a- = ∅ 52.8 mm.ut
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♦ Identification via numbers and letters on the external cam sur‐ s
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face of the escape valve at cylinder 3:

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Cylinder 3 -arrow- 1R
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Valve synchronization in the opening of 1-mm valve

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Intake opens after TDC 15,8°

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Intake closes after BDC 25,3°

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Exhaust opens before BDC 28,2°

Exhaust closes before TDC 18,7°
rrectness of i
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2.1 Valve seats - rework

nform

mercia
♦ Depth gauge
at
om
ion
c
♦ Valve seat recovery tool

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or
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ate
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53
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2. Valve command - repair
Fox 2004 ➤
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.
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Note ir se
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In case the valve is replaced during repairs, use new valve for c
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measurement.
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erm
– Measure the distance -a- between valve stem end and engine
ab
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head upper edge.

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– Calculate max. permissible reworking dimension from meas‐

h re
hole
ured distance -a-and minimum dimension.

spec
es, in part or in w
Minimum dimensions: Intake valve 43.4 mm Escape valve 43.2

t to the co
mm.
Distance measured minus minimum distance = maximum per‐
rrectness of i
mitted reworking dimension.

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Example:
- Measured distance 44,1 mm
nf
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Minimum dimension 43,4 mm

rm
m
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= Max. reworking dimension perm. 0,7 mm

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2.1.2 Reworking intake valve seat

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a =∅35.7 mm
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b = 1.6 mm C py
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Note
. The 30° angle in the valve seat base is crucial for ensuring the
correct gas flow.

Fox 2004 ➤
2.1.3 Reworking escape valve seat
a =∅31.4 mm
b = 2.7 mm
45° = Valve seat angle
2.2 Valve guides

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spec
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♦ Dial gauge
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Test sequence
nform
ercia
– Place a new valve on the guide. Valve stem end shall be

aligned with guide. Due to differences in valve stem diameters,
m
at
fit intake valves in the intake guides and exhaust valves in ex‐
om
ion
haust guides.
c
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– Determine tilting clearance. Wear limit: max. 1.3 mm.

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– Cylinder head shall be replaced if the clearance is greater than

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wear limit.
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Fox 2004 ➤
2.3 Valve stem seal - replace

equipment required
♦ Device -2036-
♦ Extractor -3047A-
♦ Fitter -3129-
♦ Lever -VW 541/1A-
♦ Supporting part -VW 541/5-
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2.3.1 Removal
nform
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(with engine head installed).

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– Remove camshaft ⇒ page 58 .

n in
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– Remove tappets and place them with contact surface turned

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downwards. When doing this, ensure that the tappets are not
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interchanged.
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– Adjust piston of respective cylinder to top dead centre (TDC). t. Cop py
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Fox 2004 ➤
– 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- .
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2.3.2 Installing
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– Install the plastic sleeve -A- supplied in the respective valve
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stem. This will prevent the new valve stem -B- from being
hole
damaged.
spec
es, in part or in w
t to the co
– 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.
rrectness of i
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orm
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Fox 2004 ir se ➤
d ran
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3 - aCyl.
uth diesel engine - Edition 02.2009 or
ac
ss
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2.4 Camshaft - remove and install
un
pt
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erm
ab
ility
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equipment required
is n
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♦ Blocking device -T10051-
spec
♦ Extractor -T10052-
t to the co
(enc. 1/2") -VAG 1331-
rrectne
Nm (enc. 1/2") -VAG 1332-
ss o
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♦ Seal -AMV 17400401-
inform
mer
atio
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Prote AG.
2.4.1 Removal
– Remove fastening screws of camshaft gear -1-.
– Remove hub camshaft gear.

Fox 2004 ➤
– Loose hub fastening screw -1-.

wage
– Use Blocking device -T10051- .Vo lks es n
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ed ran
– Loosen hub securing screw hor about 2 turns.
is tee
ut or
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spec
es, in part or in w
t to the co
– Install Puller -T10052- and align it with holes in hub.
– Install securing screws -1- into hub.
rrectness of i
– Apply effort to the hub by tightening evenly screw -2- until the
l purpos
hub is separated from the tapered section of the camshaft.
nform
ercia
Note
m
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Hold puller with a spanner while doing the above operation.
n
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– Remove the camshaft hub.
priv
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– Remove cylinder head cover.
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t.
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– Remove injector drive arm shaft.
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Note
AG.
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 ➤
– 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
AG. Volkswagen AG d
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♦ Bearing cap 4 is identified as b bearing cap 5.
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♦ Apply Sealant -AMV 17400401-
hor to seal surfaces of bearing eo
ut
caps 1 and 4, whichss are in contact with the cylinder head
a ra
c
ce
e
♦ Bearing cap 4 must align flush with outer edge of cylinder

nl
pt
du
head, because otherwise leaks may develop at the auxiliary
an
itte
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pump.
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ab
ility
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– Install the camshaft seal.
, is n
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hole
– Fit injector drive arm shaft and tighten first one bolt of each of
spec
the inner pairs, then the other bolt of each pair, and finally the
es, in part or in w
t to the co
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).
rrectness of i
– Install the hube on camshaft.
l purpos
– Tighten hub fastening screw -1-. Tightening torque: 100 Nm.

– Use Blocking device -T10051- .
nform
mercia
at
om
ion
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ate
do
priv
cum
for
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ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
– 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 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 ➤
17 – Lubrication system
1 Lubrication system components - re‐
move and install
Note AG. Volkswagen AG d

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♦ When a significant number of metal isedchips
b and shavings ap‐ ara
nte
pear in the engine oil during enginehor repair due to crankshaft eo
ut
and rod bearing wear, the oilssfilter must be replaced and the
a ra
c
oil gallery must be carefully cleaned.
ce
le
un
pt
♦ The oil level should not exceed the maximum marking - risk of
an
d
itte
y li
damage to the catalytic converter!
rm
ab
pe
ility
ot
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assembly.
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
torque
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Check oil pressure ⇒ page 70 .
nform
ercia
Oil system capacity:

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with oil filter 4.2 l.
on in
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Engine oil specification:
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Only use engine oils as per VW 505.01specification. cum

fo
en
ng
t.
Part I assembly overview ⇒ page 61 .
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Part II oil filter support disassembly ⇒ page 64 . gh ht
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Part III: oil supply tube removal and installation ⇒ page 65 . Prote
cted AG.
agen
Part I
1. Lubrication system components - remove and install 61

Fox 2004 ➤
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 AG. Volkswagen AG d
crankshaft trunnion with agen oes
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❑ Replace cranckshaft oil ut
hor eo
sealing - pulley end ss a ra
c
⇒ page 17 .
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un
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an
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3 - Engine block
itte
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erm
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4 - Gasket
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❑ Replace.
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ole,
spec
t to the co
semble ⇒ page 64 .
6 - 15 Nm + 90°
rrectne
moval.
ss
❑ First, fit upper left and
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cial p
f
lower right bolts; then,
tighten the four bolts di‐ inform
mer
agonally.
atio
om
7 - Oil dipstick
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❑ The oil level should exceed the maximum marking!

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❑ Marks ⇒ page 66
p
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fo
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ng
8 - Guide
t.
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❑ Remove to drain oil. ht. rig
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9 - 5 Nm by c lksw
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Prote AG.
10 - Guide tube
11 - 10 Nm
❑ Not applicable.
12 - Sealing ring
❑ Replace.
❑ Lubricate lightly when fitting.
13 - Cover
❑ Clean filter if dirty.
62 Rep. Gr.17 - Lubrication system

Fox 2004 ➤
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. gen AG. Volkswagen AG d
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❑ Remove and install ⇒ page olks .
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19 - Oil ejector tho
ri tee
or
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❑ For piston cooling.
ss
ce
le
❑ Check installation position: Install by turning the oil ejector counterclockwise up to the stop.
un
pt
an
d
itte
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20 - Sealing ring
rm
ab
pe
ility
❑ Replace.
ot
wit
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21 - Crankcase
h re
hole
spec
❑ Clean sealing surface before installation.
es, in part or in w
❑ Install with Silicone sealant -D 176 404 A2 - ⇒ page 68
t to the co
❑ To remove crankcase, firstly remove the transmission ⇒ Rep. Gr. 34 .
22 - Support
rrectness of i
❑ For intercooler hose.
l purpos
23 - 15 Nm
❑ To remove the rear bolts near the transmission, the latter must be removed ⇒ Rep. Gr. 34 .
nform
mercia
24 - Packing
a
com
tio
❑ Replace.
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25 - Plug, 30 Nm
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❑ Replace the plug with seal.

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t.
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26 - Gear
Co
Cop py
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❑ To oil pump.
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❑ It can be installed in one position only.
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Prote AG.
27 - 20 Nm + 90°
28 - Chain
❑ Observe fastening position ⇒ page 23 .
29 - Gear
❑ To counterbalance shaft.
30 - 100 Nm + 90°
❑ The angular torque can be performed in several stages.
❑ To loose and tighten, use Multi-point spanner -T10061-
31 - Counterbalance

Fox 2004 ➤
32 - 20 Nm
33 - Gear
34 - 8 Nm + 90°
35 - Chain tensioning element with tensioning plate.
❑ To remove, immobilise with Locking pin -T10060- .
36 - Sealing ring
❑ Not applicable.
37 - Oil level and temperature sensor -(G266)-
❑ Not applicable.
Part II
WARNING

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1 - Packing ss
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un
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❑ Replace.
an
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itte
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2 - 15 Nm + 90°
rm
ab
pe
ility

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wit
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moval.
h re
hole
❑ First, fit upper left and

spec
lower right bolts; then,

es, in part or in w
t to the co
tighten the four bolts di‐

agonally.
rrectness of i
4 - Packing
l purpos
❑ Replace.
nform
ercia
❑ To the turbocharger oil
m
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supply tube.
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6 - Oil supply tube

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❑ For the turbocompres‐

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rp
cum
sor.
fo
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ng
t.
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Co
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⇒ page 65 .
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7 - Oil pressure switch -F1- 0.7
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bar, 20 Nm Prote AG.
❑ In case of leakage, cut

and replace the sealing
ring.
❑ Checking ⇒ page 70 .
8 - Sealing cap, 25 Nm
9 - Sealing ring
❑ Replace.

Fox 2004 ➤
10 - Oil filter element

11 - Sealing plug, 10 Nm
12 - Gasket
❑ Replace.
❑ Install in the oil radiator groove.
13 - Oil radiator
❑ 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 AG. Volkswagen AG d
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⇒ Item 5 (page 64) . olksw
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3 - Packing orise nte
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❑ Replace. ss a ra
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pt
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5 - Oil supply tube
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❑ To the turbocharger.
ility
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6 - Clip
h re
ole,
7 - 25 Nm spec
t to the co
❑ Replace.
8 - Support
rrectne
9 - 10 Nm
10 - 10 Nm
ss o
cial p
11 - Connection
f inform

mer
⇒ Item 20 (page 103) .

atio
om
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12 - Turbocharger
i
or
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te
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fo
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ng
t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Fox 2004 ➤
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: n AG. Volkswagen AG do
wage
Replenish at most 0.5 l of engine oil. olks es n
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Assembly sequence ir se tee
tho
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a ac
Removal ss
ce
e
nl
– Remove noise insulation.
pt
du
an
itte
y li
– Place Drainage tank -V.A.G 1306- underneath.
erm
ab
ility
ot p
– To remove, loosen supply hose clips -6-.
wit
, is n
h re
– Disconnect safety nut -1- on oil filter bracket -4-, locking the
hole
spec
connection -2-.
es, in part or in w
t to the co
– Remove bolt -10- at rear side of engine.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
– 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 lkswage es n
o ot g
byV ua
Install in the reverse ir se sequence, observing the following: ante
d r
tho eo
au ra
c
ss
WARNING
ce
le
un
pt
an
d
itte
Oil supply line assembly shall be carried out as described be‐
y li
rm
ab
low.
pe
ility
ot
wit
, is n
h re
hole
– Screw bracket -8- with nut -7- loosely to exhaust manifold.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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ng
t.
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Cop py
t. rig
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Vo
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by
cted agen
Prote AG.
– 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 ➤
– 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

♦ Portable drill with plastic brush
♦ Silicone sealant -D176404 A2-
♦ Flat spatula
1.1.1 Removal
– 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.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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aut ra
ss c
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
1.1.2 Installation
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
♦ Check the sealant expiration date.

♦ The crankcase must be installed within 5 minutes after apply‐
rrectness of i
ing the sealant.

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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fo
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t.
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Cop py
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op Vo
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Rep. Gr.17 - Lubrication system Prote
cted AG.
agen
Fox 2004 ➤
– 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: gen AG
. Volkswagen AG
d wa oes
olks not
♦ Be 2...3 mm thick. byV gu
ara
ed nte
ris
♦ Run on inside of bolt holes region -arrows-.
tho eo
au ra
c
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
Sealing cord may not be thicker, otherwise excess sealant may pe
ility
ot
drop into crankcase and block suction tube strainer.
wit
, is n
h re
hole
spec
– Install crankcase immediately and slightly tighten all the bolts.
es, in part or in w
t to the co
Note
rrectness of i
Crankcase shall be aligned with engine block.
l purpos
– Tighten bolts to 15 Nm.
nform
ercia
– Install transmission ⇒ Rep. Gr. 34 .

m
a
com
– Tighten crankcase/transmission screws to 45 Nm.
tion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng
After installing the crankcase, the sealant should dry for approx‐
t.
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op
imately 30 minutes before replenishing with engine oil.
C py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Fox 2004 ➤
1.2 Checking the oil pressure and the oil pressure switch

equipment required
♦ Oil pressure meter -
V.A.G 1342-
♦ Test probe -VAG 1527B-
♦ Auxiliary measuring cable
set -VAG 1594C-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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thi
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sd
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Note
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Cop py
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Operation and maintenance test of visual and acoustic oil pres‐
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sure indicator ⇒ Current flow diagrams, Electrical fault finding and cop Vo
by lksw
Fitting locations
cted agen
Prote AG.

Fox 2004 ➤
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.
nA n AG G. Volkswage
At higher speeds, oil pressure may not Vexceed wage5.8 bar. If neces‐ does n
olks ot g
sary, replace the oil filter support. ed by ua
ran
ris tee
utho or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
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cted agen
Prote AG.

Fox 2004 ➤
19 – Cooling system
AG. Volkswagen AG d
agen oes
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1 Cooling system components - re‐ ol not
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d by ara
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move and install ris nte
ho eo
aut ra
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ce
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un
pt
Note
an
d
itte
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rm
ab
pe
♦ The cooling system is under pressure when the engine is hot.
ility
ot
Thus, it is necessary to reduce the pressure before doing re‐
wit
, is n
pairs.
h re
hole
spec
♦ Hose junctions are fastened by spring clamps. When doing
es, in part or in w
repairs, use spring clamps only.
t to the co
♦ To install spring clamps, we recommend using Standart-type
clamp pliers -VAS 5024A - or Hose clip pliers -VAG 1921- .
rrectness of i
l purpos
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- .
nform
ercia
Cooling system components in the body ⇒ page 73 .

m
a
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tio
Cooling system components in the engine ⇒ page 74 .
n in
r
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thi
Cooling system - drain and replenish ⇒ page 76 .
s
iva
do
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rp
cum
Coolant mixture proportions ⇒ page 76 .
fo
en
ng
t.
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Cop py
t. rig
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by c lksw
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Prote AG.
72 Rep. Gr.19 - Cooling system

Fox 2004 ➤
1.1 Cooling system components in the body
1 - Radiator
⇒ page 79 .
❑ When replacing,
change the complete
coolant.
2 - Sealing ring
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 n AG. Volkswagen AG do
the Adapter for VAG 1274 - olkswage es n
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VAG 1274/8- . d byV ua
ran
ir se tee
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8 - Air ducts auth or
ac
ss
9 - 5 Nm
ce
e
nl
pt
du
an
10 - Fan ring
itte
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erm
ab
11 - 10 Nm
ility
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wit
, is n
12 - Radiator fan
h re
hole
spec
13 - Support
es, in part or in w
❑ For radiator fan connector.

t to the co
14 - Lower cooling system hose

❑ Hose connection diagram ⇒ page 75 .
rrectness of i
15 - Radiator fan thermal switch -F18- , 35 Nm

l purpos
❑ For electric fan.

nform
ercia
❑ Starting temperatures: Stage 1 ON: 92...97 °C OFF: 84...91 °C. Stage 2 ON: 99...105 °C OFF: 91...98 °
C.
m
at
om
io
16 - Radiator lower support

n
c
in t
or
❑ Black.
his
ate
do
riv
17 - 5 Nm
p
cum
for
en
g
18 - Radiator upper support

n
t.
yi Co
op py
❑ White.
t. C rig
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Prote AG.
1. Cooling system components - remove and install 73

Fox 2004 ➤
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.
gram ⇒ page 75 .
5 - 25 Nm
6 - Hose
❑ To the lower side of the
coolant reservoir.
gram ⇒ page 75 .
7 - Fastening support
8 - Cooling system pipe n AG. Volkswagen AG do
lkswage es n
o ot g
❑ Hose connection dia‐ byV ua
d ran
gram ⇒ page 75 . ir se tee
tho
u or
a ac
9 - Sealing ring ss
ce
e
nl
❑ Replace.
pt
du
an
itte
y li
10 - Hose
erm
ab
ility
❑ To upper side of the ex‐
ot p
wit
pansion reservoir.
, is n
h re
hole
spec
gram ⇒ page 75 .
es, in part or in w
t to the co
11 - Hose
❑ To upper side of radia‐
tor.
rrectness of i
l purpos
gram ⇒ page 75 .
12 - Hose nf
ercia
o
❑ From lower side of radiator.
rm
m
atio
m
❑ Hose connection diagram ⇒ page 75 .

o
n in
or c
13 - Connection
thi
te
sd
iva
❑ For thermostat.
o
r
rp
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o
m
f
14 - 15 Nm
en
ng
t.
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op py
15 - Thermostat t. C rig
gh ht
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❑ Remove and install ⇒ page 82 . cop Vo
by lksw
cted agen
❑ Check installation position ⇒ page 82 . Prote AG.
❑ 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.

Fox 2004 ➤
3 -
olkswagen AG
Cyl. diesel engine - Edition 02.2009
wag en AG. V does
❑ Remove and install ⇒ page 80 . y Volks not
gu
b ara
ed nte
17 - Sealing ring thoris eo
au ra
ss c
ce
e
❑ Replace.
nl
pt
du
an
itte
y li
18 - Clip
erm
ab
❑ Check it is securely seated
ility
ot p
wit
, is n
19 - Coolant temperature sensor -G62- .
h re
hole
❑ With the Coolant temperature sensor -G2- .
spec
es, in part or in w
t to the co
1.3 Cooling system hose connection diagram
rrectness of i
l purpos
1 - Coolant reservoir
2 - Intake manifold
nform
ercia
3 - Engine block/cylinder head

m
at
om
io
4 - Heating system heat ex‐
n
c
in t
or
changer
his
ate
do
riv
5 - Radiator
p
cum
for
❑ For exhaust gas recircu‐
en
ng
t.
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lation.
Co
Cop py
t. rig
gh
6 - Radiator
ht
pyri by
Vo
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by c lksw
cted
7 - Oil radiator
agen
Prote AG.
8 - Water pump/thermostat

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Fox 2004 ➤ ut
ho eo
ra
a
3 - Cyl. diesel engine - Edition
ss 02.2009 c
ce
le
un
pt
1.4 Cooling system - drain and replenish
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
equipment required
hole
spec
♦ Refractometer for cooling es, in part or in w
t to the co
system fluid analysis -
T10007-
♦ Tray -V.A.G 1306-
rrectness of i
l purpos
VAS 5024A-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.

Fox 2004 ➤
AG. Volkswagen AG d
agen o
– Remove plug -arrow- for
Voldraining the cooling system.ot g
ksw es n
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– , Also, disconnect the oil radiator hose -arrows-.
rrectness of i
l purpos
Note
nform
ercia
Follow the recommendations for coolant disposal!

m
at
om
ion
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in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Fox 2004 ➤
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‐ gen AG
. Volkswagen AG
does
son, the cooling system should always (all the year round) Volkswa not
contain the described antifreeze and anti-corrosive product edb
y gu
ara
mixture. thoris nte
eo
au ra
♦ The purple Additive -G12- (as per TL VW 774 F) canss be mixed c
ce
le
with the previous red Additive -G12- ! un
pt
an
d
itte
♦ Because of its high boiling point, the coolant improves engine
y li
rm
ab
reliability under heavy loads, particularly in countries with trop‐
pe
ility
ical climates.
ot
wit
, is n
h re
♦ Antifreeze protection must be ensured to approximately -25 °
hole
spec
C (in arctic climate countries, to approximately -35 ° C).
es, in part or in w
t to the co
♦ 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%.
rrectness of i
♦ If because of climatic conditions, greater antifreeze protection
is necessary, the percentage of Additive -G12- may be in‐
l purpos
creased; however, only upto the limit of 60 % (anti-freeze

protection up to -40 °C). Where the proportion is greater, the
nform
ercia
cooling capacity and antifreeze protection will diminish.

m
a
♦ When replacing the radiator, heat exchanger, cylinder head or
com
tio
cylinder head gasket, used coolant should not be reused.
n in
r
te o
thi
s
iva
do
Recommended mixture proportions:
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rp
cum
fo
en
g
Antifreeze pro‐ Antifreeze pro‐ G 122) Water2)

n
t.
yi Co
op
tection until portion C py
t. rig
gh ht
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-25 °C 40 % 2.0 l 3.0 l p by
o Vo
by c
-35 °C 50 % 2.5 l 2.5 l
lksw
cted agen
Prote AG.
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 ➤
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

AG. Volkswagen AG d
equipment required ksw
agen oes
not
ol
yV gu
♦ Refractometer for cooling ised b ara
nte
system fluid analysis - ut
hor eo
T10007- ss a ra
c
ce
e
♦ Tray -V.A.G 1306-

nl
pt
du
an
itte
y li
erm
ab
( enc. 1/2") -VAG 1331-
ility
ot p
wit
, is n
h re
VAS 5024A-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.5.1 Removal
– Remove front bumper ⇒ Rep. Gr. 63 .
– Put front panel in the work position: ⇒ Rep. Gr. 50 .

Fox 2004 ➤
– 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:
tions ⇒ page 8 .
1.5.2 Installing
Installation is carried out by inverting the removal sequence, ob‐
serving the following:
Vehicles with air conditioning system:
tions ⇒ page 8 .
1.6 Water pump - remove and install

equipment required
AG. Volkswagen AG d
♦ Refractometer for cooling agen oes
olksw not
V
system fluid analysis - d by gu
ara
T10007- rise nte
tho eo
au ra
♦ Tray -V.A.G 1306- ss c
ce
e
nl
pt
du
an
itte
( enc. 1/2") -VAG 1331-
y li
erm
ab
ility
ot p
wit
VAS 5024A-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
1.6.1 Removal
Note
Always replace seals and gaskets.

– Loosen securing bolts -1- and carefully remove
agen
the
AG. Vpump
olkswag-2-.
en AG
d w oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.6.2 Installing
rrectness of i
The installation is carried out in removal reverse order, consider‐
ing the following:
l purpos
– Moisten new O-ring -3- with coolant.
nf
ercia
– Insert the pump -2- into engine block and tighten securing bolts
orm
-1-. Tightening torque: 15 Nm.
m
atio
om
n in
or c
thi
e
Note
t
sd
iva
o
r
rp
cu
The pump plug must face downwards.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Fox 2004 ➤ horis
eo
ut
3 - Cyl. diesel engine -ssEdition 02.2009
a ra
c
ce
le
un
pt
1.7 Thermostat - remove and install
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
equipment required
h re
ole,
spec
♦ Refractometer for cooling
system fluid analysis -
t to the co
T10007-
♦ Tray -V.A.G 1306-
rrectne
( enc. 1/2") -VAG 1331-
ss o
cial p
f
inform
VAS 5024A-
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.7.1 Removal
Note
Always replace seals and gaskets.

– Remove alternator ⇒ Rep. Gr. 27 .
– Remove the cooling system hose from the connection flange.

Fox 2004 ➤
– 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-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
1.7.2 Installing
t to the co
rrectness of i
– Moisten new O-ring -3- with coolant.
l purpos
– Insert thermostat -4- into connection flange -2- and rotate 1/4
nform
ercia
of turn (90°) to right.

m
a
com
tion in
Note
r
te o
thi
s
iva
do
The support on the thermostat must be almost vertical.

r
rp
cum
fo
en
ng
t.
yi
– Mount the connection flange -2- with thermostat -4- into engine
Co
Cop py
block. ht. rig
rig ht
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o Vo
– Tighten securing bolts -1-. Tightening torque 15 Nm. by c lksw
cted agen
Prote AG.

Fox 2004 ➤
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 AG. Volkswagen AG d
agen oes
olksw not
❑ With rubber bellows. d by V gu
ara
ise nte
❑ Remove and install. uthor eo
a ra
s c
4 - Securing bolt s
ce
le
un
pt
5 - Fuel tank cover
an
d
itte
❑ With rubber bellows. y li

erm
ab
ility
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❑ Remove and install ⇒ wit

is n
Rep. Gr. 55 . h re
ole,
spec
6 - Vent valve
❑ Checking ⇒ page 86
t to the co
❑ To remove valve, open

the clip sideways to the
rrectne
outside of the support.

❑ To remove and install,
s
remove the fuel filling

s o
pipe.
cial p
f inform
7 - Gravity valve
mer
atio
m
❑ To remove, remove the

o
n
c
right rear wheel case

i
or
n thi
cover.
te
sd
va
❑ To remove, release
i
o
pr
cum
r
locking tab and loosen

fo
en
ng
the valve upwards out of

t.
yi Co
op
filler nozzle.
C py
t. rig
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yri
❑ Check valve passage. p by
co Vo
lksw
Vertical valve: open,
by
cted agen
Prote
valve inclined at 45°:
AG.
closed.
84 Rep. Gr.20 - Supply system - Fuel tank, fuel pump

Fox 2004 ➤
8 - Fuel supply tube

9 - Spring-type clamp
n AG. Volkswagen A
10 - Fuel tank ksw
age G do
es n
y Vol ot g
❑ Support with sEngine/gearbox
ed b jack -VAG 1383A- when
ua
ran removing.
ri tee
❑ Remove aandut
ho
install ⇒ page 88 . or
a
ss c
11 - 26 ± 3 Nm
ce
e
nl
pt
du
an
12 - Vent hose
itte
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erm
ab
❑ Check that it is securely connected.
ility
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wit
13 - Vent hose
, is n
h re
❑ To gravity valve.
hole
spec
es, in part or in w
t to the co
14 - Bearing
15 - Expansion tank
rrectness of i
16 - Fuel pump
l purpos
❑ Check the flange installation position in the fuel tank ⇒ page 86

nf
ercia
o
❑ Check fuel pump ⇒ page 92 .
rm
m
atio
m
❑ With fuel gauge sensor -G-.

o
n in
or c
❑ Remove and install fuel meter sensor ⇒ page 92 .
thi
te
sd
a
❑ Clean strainer if soiled.

iv
o
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rp
cu
o
17 - Sealing ring
f
en
ng
t.
yi Co
❑ Replace if damaged. t. Cop py
rig
gh
❑ Moisten with fuel when installing the pump.
ht
pyri by
Vo
co lksw
by
18 - Circlip
cted agen
Prote AG.
❑ Remove and install with Spanner -VW 5321/9-
19 - Supply tube
❑ Secured with clip to the fuel tank.
❑ Black.
❑ Press the release button in the connection piece for removing the flange.
20 - Return pipe
❑ Secured with clip to the fuel tank.
❑ To remove the flange, press the release button in the connection piece.
1. Fuel supply system components - remove and install 85

Fox 2004 ➤
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
AG. Volkswagen AG d
agen
After fuel pump flange installation, check if supply,
olks return and vent
w oes
not
yV
pipes are still fastened to fuel tank. b gu
d ara
se ri nte
utho eo
ra
a c
ss
Check vent valve
ce
e
nl
pt
du
an
Lever in rest position: closed.
itte
y li
erm
ab
Lever pushed in the direction of arrow: open.
ility
ot p
wit
, is n
h re
hole
Note spec
es, in part or in w
t to the co
Before vent valve installation, remove fuel tank cover.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
1.2 Fuel filter - repair
1 - Supply tube
❑ From the fuel tank.
❑ White or with white
marking.
connected.
2 - Return pipe
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. agen
AG. Volkswagen AG d
oes
lksw not
❑ Check that it is securely by
Vo gu
ara
connected. rised
nte
ho eo
❑ White or with white s aut ra
c
marking. s
ce
le
un
pt
5 - Return pipe
an
d
itte
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❑ From auxiliary pump.

rm
ab
pe
ility
❑ Check it is securely
ot
wit
, is n
seated.
h re
hole

spec
es, in part or in w
6 - Fuel pipe
t to the co
7 - Cooling system hose

rrectness of i
8 - Fuel temperature sensor -G81-

l purpos
9 - Cooling system hose

10 - Fuel filter
nform
ercia
❑ Fill with diesel before installing.

m
❑ Flow direction is identified with an arrow.

com
tion in
❑ Do not interchange the connections.

r
te o
thi
s
iva
do
r
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Fox 2004 ➤
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)!
♦ Use protective gloves and eyewear when carrying out any
repairs to the fuel system! wage
e
ks s no
Vol t gu
d by ara
e nte
ris
♦ Before starting installation work, place a ugas
tho exhaust hose of eo
ra
a switched on gas exhaust system nearssthea
fuel tank opening, c
so as to absorb gases released by the fuel. If exhaust equi‐ ce
le
un
pt
ment is unavailable use a radial fan ( the motor must be out of an
d
itte
y li
air flow) with air movement rate higher than 15 m3/ hour.
erm
ab
ility
ot p
♦ Avoid skin contact with fuel! Use fuel resistant gloves!

wit
is n
h re
1.4 Cleanliness rules

ole,
spec
For jobs on the fuel / injection system, strictly observe the follow‐
t to the co
ing “6 cleaning” rules:

♦ Carefully clean all the connections and surrounding areas be‐
rrectne
fore disconnecting them.

♦ Place all the parts removed on clean surface and cover them.
ss
Do not use cloth that releases lint!

o
cial p
f in
♦ If repair work is not to be carried out immediately, open com‐

form
mer
ponents must be covered up or carefully preserved.

atio
m
♦ Install only clean components. Only remove spare parts from

o
n
c
i
or
packaging just prior to installation. Do not install components

thi
te
that have been kept out of packaging (i.e. inside the tool box,
sd
iva
o
r
etc.).
p
cum
r
fo
en
ng
♦ With system open: If possible, avoid using compressed air. If

t.
yi Co
op
possible, do not move the vehicle. C py
t. rig
gh ht
yri by
♦ Also, ensure that no diesel runs onto the cooling system ho‐ cop Vo
by lksw
ses. Hoses that may come into contact with fuel must be cted agen
Prote AG.
cleaned immediately. Damaged hoses should be replaced.
1.5 Fuel tank - remove and install


Fox 2004 ➤
♦ Torque wrench - 5 to 50 Nm ( enc. 1/2") -VAG 1331-
♦ Jack - Gearbox or engine + gearbox -VAG 1383A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
♦ Standart-type clamp pliers -VAS 5024A-
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
♦ Fuel extractor -VAS 5190-

t.
yi Co
Cop py
1.5.1 Removal
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Follow safety precautions before starting work ⇒ page 88 . cted agen
Prote AG.
– 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 ➤
WARNING
♦ The fuel and hoses in the fuel system may be very hot (risk
of burns)!
♦ Use protective gloves and eyewear when performing any
– 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 wagen AG. Volkswagen AG doe
body with a metallic wire. yV
olks s no
tg
b ua
ed ran
– Remove heat deflector between the exhaust tube and ris the fuel tee
tho
tank. sa
u or
ac
s
– Remove fastening clips from the supply pipe by using the
ce
le
un
pt
Standart-type clamp pliers -VAS 5024A- .
an
d
itte
y li
erm
ab
– Support the fuel tank by using the Engine/gearbox combo jack
ility
ot p
-VAG 1383A- .
wit
is n
h re
– Remove fuel tank securing bolts.
ole,
spec
– Lower fuel tank.
t to the co
1.5.2 Installation
rrectne
ss
♦ Vent and fuel hoses are to be installed kink-free.
o
cial p
f inform
♦ Check the firm seating of the fuel hoses.
mer
atio
♦ Do not interchange supply and return lines (return hose blue

om
or with blue marking, supply line black).

c
i
or
n thi
te
sd
iva
o
pr
cum
Note
r
fo
en
ng
t.
yi Co
op
After installing fuel meter sensor, check that supply, return and C py
t. rig
vent pipes are still fixed to the fuel tank.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Flange mark shall be aligned with fuel tank mark -arrow-.
AG.
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 ➤
1.6 Fuel pump - remove and install

♦ Spanner -VW 5321/9- or Spanner -T10334-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
1.6.1 Removal
mer
atio
om
Follow safety measures ⇒ page 88 . n

c
i
or
n thi
te
Follow cleanliness rules ⇒ page 88 .

sd
iva
o
pr
cum
r
– Check if the vehicle has code radio; if so, request respective

fo
en
ng
anti-theft code.
t.
yi Co
Cop py
– With ignition off, disconnect earth strap from battery.
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
– 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)!
♦ Use protective gloves and eyewear when performing any

Fox 2004 ➤
– Loosen the pump with Spanner -VW 5321/9 - or Spanner -

T10334- .
– Remove fuel pump and seal fuel tank opening.
AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
Note oris tee
th or
au ac
ss
When the fuel pump is to be replaced, drain it before discarding.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
1.6.2 Installation
spec
t to the co
rrectne
Note
ss o
♦ Do not fold fuel level sensor when installing.
cial p
f inform
♦ Insert flange sealing or the dry fuel pump into the fuel tank
mer
opening.
atio
om
n
c
♦ Moisten the seal with fuel only when installing the flange or
i
or
n thi
e
fuel pump.
t
sd
iva
o
pr
c
♦ Make sure the fuel pipes are firmly seated.
um
r
fo
en
ng
t.
yi
♦ After installing the fuel pump flange, check whether the supply,
Co
op py
return and vent pipes are still fastened onto the fuel tank.
t. C rig
gh ht
pyri by
Vo
♦ Flange mark shall be aligned with fuel tank mark -arrow-.
co lksw
by
cted agen
Prote AG.
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


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Fox 2004 ➤
ise nte
r
ut
ho 3 - Cyl. diesele oengine
ra - Edition 02.2009
a c
ss
♦ Portable multimeter -VAG 1526C- or Multimeter -V.A.G 1715-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Auxiliary cable set -V.A.G 1594 A-
nform
ercia

m
a
com
tion in
Test conditions
r
te o
thi
• The fuses must be in order.
s
iva
do
r
rp
cum
• The battery voltage must be at least 11.5 V.
fo
en
ng
t.
yi Co
• All power consuming components, like lights and rear window Cop py
t. rig
demister, must be off. opyri
gh by
Vo
ht
by c
Check operation and power supply voltage
lksw
cted agen
Prote AG.
– 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 ➤
– 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 agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
The Multimeter -V.A.G 1715o-ristest probe can also be inserted be‐
ed
nte
tween the contact -1- connector
aut
h and the fuel pump by using the eo
ra
adapter cables of the Multimeter
ss -V.A.G 1715 - . c
ce
le
un
pt
an
d
– Connect contacts -4- of connector and fuel pump by using the

itte
y li
adapter cables from -V.A.G 1594 A- .
rm
ab
pe
ility
ot
– Start engine and run at idle speed.
wit
, is n
h re
– Measure current at fuel pump. Specification: 6,3...7.8 A.
hole
spec
es, in part or in w
– If the values measured lie outside the specifications:
t to the co
– Replace fuel pump ⇒ page 91 .
rrectness of i
1.9 Accelerator mechanism - repair
l purpos
1 - Support
nform
ercia
❑ Remove and install ⇒

m
Rep. Gr. 46 .
a
com
tion in
2 - Connector
r
te o
thi
❑ Black, 6-pin. s
iva
do
r
rp
cum
3 - Accelerator pedal position

fo
en
ng
sensor -G79-
t.
yi Co
Cop py
❑ Not adjustable.
t. rig
gh ht
yri by
❑ Accelerator pedal posi‐
op Vo
by c lksw
cted
tion sensor transmits
agen
Prote AG.
the pedal position to en‐
gine command unit.
❑ Remove feet rest area
cover to remove sensor.
4 - 10 Nm

Fox 2004 ➤
1.10 Auxiliary pump - check

♦ Pressure test equipment -VAS 5187-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Vehicle diagnosis, measurement and information system -
nf
ercia
o
VAS 5051A/52- with Diagnostic cable (3 m) -VAS 5051/5-
rm
m
atio
m
Test conditions
o
n in
or c
thi
• Coolant temperature at least 85 °C.

te
sd
iva
o
r
• Injectors must be in order.

rp
cu
o
m
f
en
ng
t.
• Fuel filter and pipes must not be blocked. Cop
yi Co
py
t. rig
• The check valve in the fuel supply hose must be in order. opyri
gh by
Vo
ht
by c lksw
Test sequence Prote
cted AG.
agen
– Remove plug -arrow-.

Fox 2004 ➤
– 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.
AG. Volkswagen AG d
– Press the ← key. agen oes
olksw not
V gu
by ara
– Select function 06 End the test function key. orised
nte
h eo
ut ra
– Switch off ignition. ss a c
ce
e
nl
If the specification is not obtained:
pt
du
an
itte
y li
– Replace auxiliary pump ⇒ page 97 .
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
After removing pressure gauge unit, tighten plug at 25 Nm. Al‐
t to the co
ways replace seal.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Fox 2004 ➤
1.11 Auxiliary pump - remove and install

equipment required
(enc. 1/2") -VAG 1331-
♦ Vacuum pump -VAG 1390-
♦ Fluid container -
V.A.G 1390/1-
VAS 5024A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Fox 2004 ➤
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-.
AG. Volkswagen AG d
– Remove auxiliary pump -4- from cylinder head.. agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
– Pull auxiliary pump -4- slightly upwards and remove return
ility
ot p
pipe -3- (blue marking).
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
1.11.2 Installation
o
n in
or c
thi

te
sd
iva

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
♦ Ensure proper seating of auxiliary pump coupling in camshaft.
c by lksw
cted agen
Prote AG.
♦ Always replace auxiliary pump seals.
– Fit return pipe -3- (blue marking) to auxiliary pump return con‐
nection.

Fox 2004 ➤
3
. Volkswage
- Cyl. diesel engine - Edition 02.2009
AG n AG d
agen oes
olksw not
– Install auxiliary pump and tighten upper d b securing bolts
yV to 20 gu
ara
Nm. rise nte
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ut ra
– Tighten lower securing bolts sto
s a 10 Nm. c
ce
le
un
– Fit supply pipe -2- (white marking) to auxiliary pump supply
pt
an
d
connection and vacuum hose -1- from servo-assisted brake to
itte
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rm
the auxiliary pump -4-.
ab
pe
ility
ot
– Connect pipe -1- (white marking) to fuel filter.
wit
, is n
h re
– Connect the Vacuum pump -VAG 1390- with the Fluid con‐
hole
spec
tainer -VAG 1390/1 - to return pipe.
es, in part or in w
t to the co
– Activate Vacuum pump -VAG 1390- until no more fuel comes
from the return pipe. Take care not to suck fuel into the vaccum
pump.
rrectness of i
– Fit return pipe -2- (blue marked) in the fuel filter.
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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Cop py
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by
1.11.3 Checking for internal leaks
cted agen
Prote AG.
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.

♦ 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 ➤
– 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.
AG. Volkswagen AG d
agen oes
olksw Note not
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rise nte
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To turn the pressure
auth regulating valve -2- the knob must be pulled
eo
ra
upwards. s s c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
– Connect compressed air hose -1- (compressed air source) to
is n
h re
tester unit -V.A.G 1687- .
ole,
spec
t to the co
Note
If there is water in the sight glass, drain at water drain screw -6-.
rrectne
– Open valve -3-.
ss o
cial p
f
– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
inform
mer
atio
Caution
om
n
c
i
or
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The maximum test pressure lies by 1.3 bar and this must not
te
sd
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be exceed.
iv
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t.
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op
– Open valve -4- and wait until the test circuit is filled. If neces‐ C py
t. rig
sary readjust pressure to 1.0 bar.
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pyri by
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by
– Close valve -3- to retain pressure and observe the pressure cted agen
Prote AG.
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 ➤
21 – Overcharge - turbo
1 Overcharge system with turbocharg‐ AG . Volkswagen AG
agen does
olksw not
er
V gu
by ara
ed nte
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s
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e
1.1 Safety measures
nl
pt
du
an
itte
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erm
ab
WARNING
ility
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wit
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h re
During assembly work, especially within the engine compart‐
hole
spec
ment, due to the lack of space, bear in mind the following :
es, in part or in w
t to the co
uum) and electric cables must be restored to original
rrectness of i
positions.
l purpos
♦ To provide easy access to all the moving or hot parts.
nf
ercia
o
If during a test drive it is necessary to use test and measuring
rm
equipment, observe the following:
m
atio
om
n in
c
♦ Always install test and measuring equipment on the back seat

or
thi
to be operated by someone from there.
te
sd
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rp
If test and measuring equipment are operated from the passenger
cu
o
m
f
seat, the person seated there may be injured should the airbag
en
ng
t.
yi
activate in case of accident.
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1.2 Cleanliness rules pyri by
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When working on the overcharge system, pay careful attention to
AG.
the following cleanliness rules :

♦ 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.
possible, do not move the vehicle.
1.3 Turbocharger - remove and install

Follow safety measures ⇒ page 101 .
Follow cleanliness rules ⇒ page 101 .
1. Overcharge system with turbocharger 101

Fox 2004 ➤
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.swagen AG. Volkswagen AG does
k not
Vol
♦ Before installing the oil supply pipe,
ed fill the turbocharger,
by gu
ara
through the connection point, with
tho engine oil.
ris nte
eo
au ra
♦ After installing the turbocharger,
ss run the engine during at idle c
ce
e
speed for about 1 minute. Do not accelerate the engine. This

nl
pt
du
will ensure the turbocharger is properly lubricated.
an
itte
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erm
ab
♦ Always replace self-locking nuts.
ility
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Hoses with coupling connections
h re
hole
spec
es, in part or in w
t to the co
Note
All the overcharge system hoses are fastened with spring clamps
rrectness of i
or connections. Always check the following points in the connec‐
tions:
l purpos
nform
ercia
– Release the connection by pulling the fixing clip -arrow-, with‐

out using tools.
m
at
om
io
– When assembling, make sure the retaining tabs -A- are firmly
n
c
in t
r
secured.
o
his
ate
do
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for
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102 Rep. Gr.21 - Overcharge - turbo

Fox 2004 ➤
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
AG. Volkswagen AG d
agen oes
3 - From the intercooler Volksw not
gu
by ara
d
4 - Gasket rise nte
tho eo
u
❑ Replace. ss a ra
c
❑ Covering (fillet) towards
ce
le
un
pt
the intake manifold.
an
d
itte
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rm
ab
5 - 25 Nm
pe
ility
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wit
6 - Gasket
, is n
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❑ Check installation posi‐
hole
spec
tion.
es, in part or in w
t to the co
7 - From the air filter
8 - Support
rrectness of i
❑ From heat deflector.
l purpos
9 - Washer
10 - 25 Nm
nform
ercia
11 - Heat deflector
m
a
com
ti
❑ Fasten on the bracket

on in
r
te o
thi
12 - Hollow screw, 15 Nm
s
iva
do
r
13 - Packing
rp
cum
fo
en
g
❑ Replace.
n
t.
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Cop py
14 - Hose
t. rig
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❑ To Electromagnetic valve for limiting charge pressure -N75- . cop Vo
by lksw
cted agen
Prote AG.
15 - Oil return pipe, 30 Nm
❑ To engine block.
16 - 15 Nm
17 - Gasket
❑ Replace.
18 - Front exhaust pipe
19 - 25 Nm
❑ Replace.
❑ 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.

AG. Volkswagen AG d
agen oes
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V gu
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Fox 2004 ➤ horis
eo
ut
ss a ra
c
ce
le
un
pt
21 - Oil supply tube
an
d
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❑ From oil filter support.
erm
ab
ility
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❑ Before installing, check oil supply tube for continuity.
wit
is n
❑ Before installing, fill turbocharger with engine oil through the oil supply tube connection.
h re
ole,
spec
t to the co
22 - 10 Nm
23 - Support
rrectne
1.4 Intake air cooling system (intercooler)
ss o
cial p
f
components - remove and install
inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a
♦ All the hoses are fastened by clamps.

iv
o
pr
cum
r
fo
♦ When required, use sliding agent (water without additive). Do
en
ng
t.
yi
not use sliding agents containing oil.
Co
Cop py
t. rig
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♦ When repairing, remove oil from the hose connections and
ht
pyri by
ends.
o Vo
by c lksw
cted agen
Prote AG.
♦ Overcharge system must be free of leaks.
104 Rep. Gr.21 - Overcharge - turbo

Fox 2004 ➤
1 - Air ducts
2 - Intercooler
3 - 8 Nm
4 - Sealing ring
5 - Intake manifold pressure
sensor -G71- with Intake mani‐
fold temperature sensor -G72-
6 - Support
7 - 5 Nm
8 - Hose
9 - Tube
n AG . Volkswagen AG
10 - From exhaustksgas
agerecircu‐ does
l w not
lation valve by Vo gu
ara
d
ise nte
11 - From
ut
ho the air filter
r eo
ra
sa c
12 - sFrom head cover ce
le
un
pt
13 - Tube
an
d
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erm
ab
ility
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15 - Tube
is n
h re
ole,
16 - Support
spec
❑ From tube.
t to the co
❑ Bolted to crankcase.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤
23 – Supply system - mechanical injection (diesel)

AG. Volkswagen AG d
agen oes
1 Maintaining the direct injection Diesel d by Volksw not
gu
ara
system uthorise nte
eo
ra
s a c
The direct injection diesel system command unit has a fault mem‐ s
ce
e
ory. Before performing repairs, and for fault location, refer to the
nl
pt
du
an
fault memory ⇒ page 115 .
itte
y li
erm
ab
Safety measures ⇒ page 107 .
ility
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Cleaning rules ⇒ page 107 .
h re
hole
spec
1.1 Installation locations - overview
es, in part or in w
t to the co
Components A to D are not shown in the illustration.
rrectness of i
A - Brake pedal switch -F47- or
Brake light switch -F-
l purpos
❑ Together in one case, in

the feet compartment,
nform
ercia
on the brake pedal.

m
at
B - Accelerator pedal position
om
io
sensor -G79- and Sensor 2 of
n
c
in t
or
accelerator pedal position -
his
ate
G185-
do
priv
cum
❑ At the feet compart‐
for
en
g
ment, on the accelerator

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t.
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op
pedal. C py
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C - Clutch pedal switch -F36-
p by
co Vo
by lksw
cted
❑ In feet compartment, on
agen
Prote AG.
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- .
106 Rep. Gr.23 - Supply system - mechanical injection (diesel)

Fox 2004 ➤
6 - Air mass meter -G70-

7 - Air filter
8 - Auxiliary pump
AG. Volkswagen AG d
9 - Vacuum pump ksw
agen oes
not
Vol
by gu
10 - Connector ised ara
nte
or
❑ For Pump / injector
aut
h valve of cylinder 1 -N240- ... Pump / injector eo
r a valve of cylinder 4 -N243- .
ss c
11 - Fuel temperature sensor -G81-
ce
e
nl
pt
du
an
12 - Engine speed sensor -G28-
itte
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erm
ab
13 - Thermostat valve
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wit
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14 - Glow plugs
h re
hole
spec
15 - Hall Sensor -G40- Hall (G40) Sensor
es, in part or in w
❑ For the camshaft position.
t to the co
16 - Fuel filter
rrectness of i
l purpos
1.2 Safety measures
nf
ercia
o
WARNING
rm
m
atio
om
During assembly work, especially within the engine compart‐
n in
or c
ment, due to the lack of space, bear in mind the following:

thi
te
sd
iva

r
rp
cu
o

f
en
ng
t.
uum) and electric cables must be restored to their original
yi Co
op
positions.
C py
t. rig
gh ht
yri by
♦ Provide easy access to all moving or hot parts.
op Vo
by c lksw
cted agen
Prote AG.
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:
1. Maintaining the direct injection Diesel system 107

Fox 2004 ➤

n AG . Volkswage
♦ If repair work is not to be carried out
wageimmediately, openocom‐
n AG d
es n
ponents opened must be covered Volks up or carefully preserved. ot g
by ua d ran
ise
♦ Install only clean components.
ut
ho
r
Only remove spare parts from tee
or
packaging just priorss to installing them. Do not install compo‐
a ac
nents that have been kept out of packaging (i.e. inside the tool
ce
le
un
box, etc.).
pt
an
d
itte
y li
erm
ab
possible, do not move the vehicle.
ility
ot p
wit
is n
♦ Also, ensure that no diesel runs onto the cooling system ho‐
h re
ole,
ses. Hoses coming in contact with fuel must be cleaned im‐
spec
mediately. Damaged hoses should be replaced.
t to the co
1.4 Intake manifold valve - repair
The intake manifold valve closes for approx. 3 seconds when
rrectne
stopping the engine, and then opens again. This reduces the stop
jerking movement.
ss o
cial p
f in
1 - Intake manifold
form
mer
atio
2 - Intake connection flange
om
n
c
❑ With exhaust gas recir‐

i
or
culation valve. n thi

te
sd
iva
o
pr
3 - Sealing ring
um
r
fo
en
ng
❑ Replace.
t.
yi Co
Cop py
4 - 10 Nm ht. rig
rig ht
py by
o Vo
5 - From the intercooler
by c lksw
cted agen
Prote AG.
6 - Intake manifold valve motor
-V157-
7 - 10 Nm

Fox 2004 ➤
1.5 Injectors - repair

♦ Follow cleanliness rules ⇒ page 88 .
♦ Always replace retainers and sealing rings.
WARNING

torque
1 - 20 Nm + 90°
moval.
2 - Rocker arm shaft
❑ With rocker arm. n AG. Volkswagen AG do
wage es n
❑ Remove andy Vinstall
olks ot g
⇒ page 112
ised b . ua
ran
r tee
ho
3 - Self-locking
sa
ut nut or
ac
s
4 - Set screw
ce
le
un
pt
an
d
❑ Replace.
itte
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rm
ab
5 - Ball head pin
pe
ility
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wit
❑ Replace.
, is n
h re
hole
6 - Injectors
spec
es, in part or in w

t to the co
⇒ page 112 .
7 - Sealing ring
rrectness of i

l purpos
8 - Sealing ring
nform
ercia
9 - Sealing ring
m
a
com

ion in
r
te o
10 - Heat insulation sealing

thi
s
iva
do
❑ Replace.
r
rp
cum
fo
11 - Circlip
en
ng
t.
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op py
12 - Cylinder head t. C rig
gh ht
pyri by
13 - Tensioning block
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by c lksw
cted agen
Prote AG.
14 - 12 Nm +270°
moval.
1.6 Sealing ring for injectors - remove and

install

Fox 2004 ➤
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. gen AG
. Volkswagen AG
d a oes
ksw not
Vol
1.6.2 Installation ed
by gu
ara
nte
oris eo
th
au ra
c
ss
Note
ce
e
nl
pt
du
an
itte
♦ Always use the assembly sleeves to fit the rings. If the as‐ y li
erm
sembly sleeves are not used, the rings may be damaged. ab

ility
ot p
wit
♦ Gradually introduce the rings with no coloured markings. Then
, is n
h re
check that the rings are correctly positioned in their respective
hole
spec
grooves. Ring size decreases towards nozzle.

es, in part or in w
t to the co
♦ Prevent the rings from rolling when sliding them on. The rings
must not be twisted when seated on the injector.
rrectness of i
– Pull the heat insulation cover with the fastening clip.

l purpos
– Carefully clean the seating surfaces of the injector ring.

– Slide Assembly sleeve -T10056/1- to stop position on unit in‐
nform
ercia
jector.
m
at
om
– Slide upper ring carefully towards assembly sleeve and into

ion
c
injector seat.
in t
or
his
ate
– Remove assembly sleeve.

do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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by
cted agen
Prote AG.

Fox 2004 ➤

jector.
– Slide intermediate ring carefully towards assembly sleeve and
into injector seat.

jector.
– Slide lower ring carefully towards assembly sleeve and into
injector seat.
– Install the heat insulation cover with the fastening clip.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Fox 2004 ➤ agen
AG. Volkswagen AG d
oes
ksw not
3 - Cyl. diesel engine - Edition 02.2009 by Vol
gu
ara
d
rise nte
o eo
1.7 Injectors - remove and install
th
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
equipment required
ab
pe
ility
ot
wit
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h re
♦ Multi-tooth Socket -3410-
hole
spec
es, in part or in w
♦ Special wrench, long reach
t to the co
-T10054-
♦ Extractor -T10055-
rrectness of i
l purpos
(enc. 1/2") -VAG 1331-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor eFox
or 2004 ➤
u
ss a 3 - Cyl. diesel engine - Edition ac 02.2009
ce
e
nl
pt
du
– Position the Puller -T10055- into the slot on the injector side
an
itte
y li
instead of the tensioning block.
erm
ab
ility
ot p
– Pull the injector out of cylinder head seat with gentle taps.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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1.7.2 Installation
Co
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t. rig
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Vo
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cted agen
Note Prote AG.
♦ 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 ➤
– 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°. AG. Volkswagen AG d
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– Fit the Bracket -VW 387- onto the set screw as shown. ised b ara
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– Turn crankshaft in the engine rotation direction until rocker
s aut arm ra
c
roller is at the top of drive cam. Roller side -arrow A- positioned
s
ce
e
at the highest point of dial gauge -arrow B- positioned at the

nl
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lowest point.
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ab
– Remove dial gauge.
ility
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– Turn set screw inwards into rocker arm until a firm resistance
h re
is noted (injector positioned at stop).
hole
spec
es, in part or in w
t to the co
rrectness of i
– Turn set screw 225° back off stop.
l purpos
– Hold set screw in this position and tighten the self-locking nut
to 30 Nm.
nform
ercia
– Fit injector connector and install cylinder head cover and tim‐
ing belt guard.
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3 - Cyl. diesel engine - Edition 02.2009 or ac
s
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2 Engine command unit
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2.1 Engine command unit - remove and in‐
h re
hole
spec
stall
es, in part or in w
t to the co
– Before removing engine command unit, refer to the command
unit ID and this respective code ⇒ page 115 .
rrectness of i
2.1.1 Removal
l purpos
– Switch off ignition.
– Remove the windscreen wiper blades and the lower coating
nform
ercia
of the windscreen frame.
m
at
om
i
– Release the connector on the engine command unit and pull
on
c
it off.
in t
or
his
ate
– Push clips -arrows- outwards and pull command unit out.
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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
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis cable (5 m)

-VAS 5051/3-
2. Engine command unit 115

Fox 2004 ➤
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.
AG. Volkswagen AG d
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– Start the engine and run it at idle speed. Volksw not
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Only when engine does not run: horis nte
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– Switch ignition on. ss c
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un
Select operation mode
pt
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– Press on the Vehicle self-diagnosis .
erm
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Select vehicle system
wit
is n
h re
ole,
– Press on the 01 Engine electronic system .
spec
The command unit ID and the code will be indicated on the dis‐
t to the co
play.
Select diagnosis function:
rrectne
– Press on the 02 Query fault memory on the display.
s
– If no faults are stored in engine command unit, the display
s o
shows “0 faults found”.
cial p
f inform
mer
– If there are faults stored in the engine command unit, they will
atio
appear sequentially on the display.
om
n
c
i
– Press ← key.
or
n thi
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– Press on the 05 Erase fault memory on the display.

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– Press 06 End the test function key.

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2.3 Adjusting functions and components pyri by
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AG.
♦ 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 ➤
– Select 01 systems with self-diagnosis .

– Select engine control .
– Select functions .
– Select function or component .
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2. Engine command unit 117

Fox 2004 ➤
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.
WARNING

torque
AG. Volkswagen AG d
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118 Rep. Gr.26 - Exhaust system

Fox 2004 ➤
1 - Gasket
❑ Replace.
2 - Self-locking nut
❑ 25 Nm
moval.
3 - Support strap
wage
e ks s no
Vol t gu
4 - Front exhausted pipe with cat‐
by ara
alytic converter
horis nte
eo
t
au ra
5 - Marking
ss c
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pt
6 - Dimension -a- = 5 mm
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7 - Double clamp
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8 - Self-locking nut
wit
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h re
❑ 40 Nm
hole
spec
es, in part or in w
moval
t to the co
9 - Support
❑ With support strap.
rrectness of i
l purpos
10 - 25 Nm
nform
ercia
11 - Rear silencer
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1. Exhaust system components - remove and install 119

Fox 2004 ➤
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- . agen
AG. Volkswagen AG d
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♦ The tapered plunger of the Exhaust gas recirculation valve - ed by V gu
ara
N18- enables the cross-section variation in function of thethoris nte
eo
different plunger positions. s au ra
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♦ The control by pulses makes feasible all the valve opening
ce
le
un
pt
positions.
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2.1 Exhaust gas recirculation system components - remove and install
h re
ole,
spec
t to the co
1 - Intake manifold
2 - Sealing ring
rrectne
❑ Replace.
3 - Intake connection flange
ss o
cial p
f
4 - Exhaust gas recirculation
inform
valve -N18-
mer
❑ Integral part of intake
atio
m
flange
o
n
c
i
or
n thi
❑ Can only be replaced to‐
te
sd
a
gether with the intake

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flange.
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5 - Intake manifold valve motor
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6 - 10 Nm
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7 - From the intercooler
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
120 Rep. Gr.26 - Exhaust system

Fox 2004 ➤
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.
olkswagen AG
en AG. V
6- Vacuum connection (in the non-return
ksw valve to servo
ag does
not
Vol
brake ). ed
by gu
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7- Exhaust gas recirculation
au
tho valve. eo
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2. Exhaust gas recirculation system 121

. Volkswagen AG
Fox 2004 ➤ wage
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olks not
3 - Cyl. diesel engined b-yEdition 02.2009
V gu
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28 – Chamber pre-heating system

s s c
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un
pt
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1 Chamber pre-heating system - check
ab
pe
ility
ot
wit
, is n
h re
hole
♦ Portable multimeter -VAG 1526C-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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♦ 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.
122 Rep. Gr.28 - Chamber pre-heating system

Fox 2004 ➤
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

♦ Auxiliary measuring cable set -VAG 1594C-
♦ Spanner -3320- agen

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es, in part or in w
t to the co

rrectness of i
Test conditions
l purpos
• Battery voltage at least 11.5 V

• Ignition switched off.
nform
ercia
Test sequence
m
a
com
tio
– Remove heating plug connectors.

n in
r
te o
thi
s
iva
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1. Chamber pre-heating system - check 123

AG. Volkswagen AG d
agen oes
Fox 2004 ➤ olksw not
byV gu
ara
3 - Cyl. diesel engine - Edition 02.2009 rised
nte
ho eo
aut ra
– Connect the Test probe -VAG 1527B- wire, using the Meas‐ ss c
ce
le
urement auxiliary cable set -VAG 1594C- , to the battery
un
pt
positive (+) terminal.
an
d
itte
y li
rm
ab
– Position the Test probe -VAG 1527B- on each heating plug,
pe
ility
one-by-one. Diode lights up: heating plug OK. If diode does
ot
wit
, is n
not light up: replace heating plug.
h re
hole
spec
– Remove and install heating plugs with Spanner -3320- . Tight‐
es, in part or in w
ening torque: 15 Nm.
t to the co
02.09
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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124 Rep. Gr.28 - Chamber pre-heating system

3 - Cyl. Diesel Engine PDF

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Service

15 - Cylinder head, valve control mechanism

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Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R007720

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 Engine - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

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

20 - Supply system - Fuel tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.7 Fuel meter sensor - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

1.8 Fuel pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

1.10 Auxiliary pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

23 - Supply system - mechanical injection (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1.1 Installation locations - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.3 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.4 Intake manifold valve - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

28 - Chamber pre-heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

1.1 Engine number

Cylinder volume l 1,4

Power kW / rpm 51/4000

Torque Nm / rpm 155/1600 to 2800 ab

Bore ∅Ø mm 79,5 wit

Compression rate 19,5

Catalytic converter yes

10 – Cylinders, engine block, support, cover

Special tools and workshop

2 Rep. Gr.10 - Cylinders, engine block, support, cover

♦ Support bracket -10-222A- with Rack -10-222A/1-

1. Engine - remove and install 3

Check whether vehicle has code radio, if so obtain the anti-theft

– The engine is removed downwards, along with transmission.

to reduced existing space, consider the following:

– With ignition switched off, disconnect battery earth lead.

– Remove connecting pipe between intercooler and intake con‐

4 Rep. Gr.10 - Cylinders, engine block, support, cover

– Release the radiator cooling system hoses from the engine by

– Remove engine support -1- and engine console -2-.

– Disconnect right-hand drive shaft⇒ Rep. Gr. 40 . ion

– 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.

1. Engine - remove and install 5

– Install support pin to the engine bracket-1- with one washer

– Remove securing bolts from the bottom of engine/gearbox.

Use Stepladder -VAS 5058- to remove the spindle.

– Separate engine from gearbox by carefully lowering it and us‐

1383A;- remove it from below.

1.2 Engine - fix on assembly stand

6 Rep. Gr.10 - Cylinders, engine block, support, cover

On hooks and pins, use safety locks -arrows-.

♦ Positions numbered 1...4 on suspension bar facewatoward

considering the following:

Assembly support tightening torques ⇒ page 8 .

– Install drive shaft ⇒ Rep. Gr. 40 .

1. Engine - remove and install 7

1.4 Tightening torque