Volkswagen Fox 2004 Workshop Manual
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Volkswagen Fox 2004 Workshop Manual

3 - cyl. diesel engine
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Service
Workshop Manual
Fox 2004 ➤
3 - Cyl. diesel engine
Engine ID
Edition 02.2009
Service Department. Technical Information
BNM

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Summary of Contents for Volkswagen Fox 2004

  • Page 1 Service Workshop Manual Fox 2004 ➤ 3 - Cyl. diesel engine Engine ID Edition 02.2009 Service Department. Technical Information...
  • Page 2 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...

  • Page 3: Table Of Contents

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Contents 00 - Technical data ........... .
  • Page 4 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 20 - Supply system - Fuel tank, fuel pump ........84 Fuel supply system components - remove and install .

  • Page 5: Technical Data

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 00 – Technical data Technical data 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‐...

  • Page 6: Cylinders, Engine Block, Support, Cover

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 10 – Cylinders, engine block, support, cover Engine - remove and install Special tools and workshop equipment required ♦ Lifting tackle -2024A- ♦ Engine and gearbox sup‐ port -T10012- ♦...
  • Page 7 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ 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...

  • Page 8: Removal - Indications

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Modifying Engine bracket -T10012- – If the modification has not yet been carried out, drill an addi‐ tional hole -a- to the prescribed dimensions at the same height as the other holes.
  • Page 9 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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‐...

  • Page 10: Engine - Fix On Assembly Stand

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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-.

  • Page 11: Notes Regarding Installation

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 12: Tightening Torque

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Tightening torque Location Tightening tor‐ Screws, nuts 10 Nm 20 Nm M 10 45 Nm M 12 60 Nm Different tightening torques Front exhaust and turbocharger pipe 25 Nm...

  • Page 13: Crankshaft, Pistons

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 13 – Crankshaft, pistons Engine - dismantle and assemble Note Where large quantities of metal shavings and filings are de‐ ♦ tected in the engine oil during repair required as a result of crankshaft and connecting rod bearing wear, the oil filter must be replaced and the oil channels carefully cleaned.
  • Page 14 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ⇒ page 10 ⇒ page 11 ⇒ page 12 Part I 1 - Timing belt guard - upper part 2 - Timing belt ❑ Mark rotation direction before removal.
  • Page 15 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 16 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 15 - Tandem pump ❑ For supplying fuel and vacuum. ❑ Remove and install ⇒ page 97 ❑ Check ⇒ page 95 16 - 25 Nm 17 - Supply hose ❑...
  • Page 17 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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‐...

  • Page 18: Poly-V Belt - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 21 - 25 Nm 22 - Oil crankcase ❑ Clean sealing surface before installation. ❑ Install with Silicone sealant -D 176 404 A2 - ⇒ page 68 ❑ To remove crankcase, first remove the transmission ⇒ Rep. Gr. 34 .
  • Page 19 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Turn tensioning element in arrow direction to relieve tension on Poly-V belt. – Lock tensioning element with Retaining pin -T10060A- . – Remove Poly-V belt. 1.1.2 Installation – The installation is carried out by inverting the removal se‐...
  • Page 20 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Belt path for vehicles with air conditioning. Rep. Gr.13 - Crankshaft, pistons...

  • Page 21: Crankshaft Flanges And Flywheel - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Crankshaft flanges and flywheel - re‐ move and install Note Clutch repairs: ⇒ Rep. Gr. 30 . WARNING Always replace self-locking nuts and screws subject to angular torque 1 - Seal ❑...

  • Page 22: Crankshaft Oil Seal, Pulley Side - Replace

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ❑ 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.
  • Page 23 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Remove crankshaft gear. To do this, immobilise gear with the Lock -3415- . – To guide the seal Extractor -3203- , install the gear fastening screw manually up to the crankshaft stop.

  • Page 24: Crankshaft Seal Flange - Replace

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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 25 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Remove crankshaft gear. To do this, lock gear with the Lock -3415- . – Drain engine oil. – Remove crankcase ⇒ page 68 – Loosen front seal flange.
  • Page 26 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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: ♦...

  • Page 27: Counterbalance Shaft And Retaining Frame - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Counterbalance shaft and retaining frame - remove and install Note All bearing and running surfaces must be lubricated before as‐ sembly. WARNING Always replace self-locking nuts and screws subject to angular...
  • Page 28 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ❑ 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.

  • Page 29: Counterbalance Shaft - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Counterbalance shaft - remove and install Special tools and workshop equipment required ♦ Pin -T10060- ♦ Multi-point spanner - T10061- ♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- ♦...
  • Page 30 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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.
  • Page 31 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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 ♦...
  • Page 32 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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-.

  • Page 33: Crankshaft - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Crankshaft - remove and install Note Before removing crankshaft, make sure that a proper surface ♦ has been prepared to ensure that the speed sensor rotor is not damaged, or does not touch another item.

  • Page 34: Crankshaft Dimensions

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 8 - Crankshaft ❑ See notes before removing ⇒ page 29 ❑ Axial clearance new: 0.07...0.17 mm. Wear limit: 0.37 mm. ❑ Check radial clearance with Plastigage. New: 0.03...00.08 mm. Wear limit: 0.17 mm.
  • Page 35 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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 4. Crankshaft - remove and install...

  • Page 36: Pistons And Connecting Rods - Dismantle And Assemble

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Pistons and connecting rods - dis‐ mantle and assemble Note All bearing and running surfaces must be lubricated before as‐ sembly. WARNING Always replace self-locking nuts and screws subject to angular...
  • Page 37 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 38 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Check cylinder diameters Special tools and workshop equipment required ♦ Precision internal micrometer 50...100 mm – Take measurements at three different cross positions, in both lateral -A- and longitudinal -B- directions, as illustrated. Max.
  • Page 39 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ Measurement tool -VW 382/7- ♦ Universal measurement tool -VW 385/17- Test sequence – The piston projection at TDC must be measured when instal‐ ling the new pistons. Depending on the piston projections,...

  • Page 40: Piston And Cylinder Dimensions

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Piston and cylinder dimensions Dimension for fin‐ ∅ Piston ∅ cilinder ishing Basic dimension 79,47 79,51 1. rework 79,97 80,01 Rep. Gr.13 - Crankshaft, pistons...

  • Page 41: Cylinder Head, Valve Control Mechanism

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 15 – Cylinder head, valve control mechanism Cylinder head - remove and install Check compression ⇒ page 49 Note When mounting a replacement head with the camshaft moun‐ ♦...
  • Page 42 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1 - Mechanical distribution up‐ per cover 2 - Timing belt ❑ Before removing, mark operation direction. ❑ Check wear. ❑ Do not bend. ❑ Remove, install, and ad‐...
  • Page 43 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 17 - Oil filling nozzle ❑ Replace. 18 - Cover ❑ Replace seal if damaged. 19 - Gasket ❑ Replace if damaged. 20 - Support ❑ With fuel tube/hose.
  • Page 44 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 45: Timing Belt - Remove And Install, Adjust

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Timing belt - remove and install, adjust Special tools and workshop equipment required ♦ Diesel injection pump lock‐ ing pin -3359- ♦ Pin wrench -3387- ♦ Crankshaft stop -T10050- ♦...
  • Page 46 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1.1.1 Removal Note Adjustment work on timing belts should only be carried out on cold engines, as the indicator on the tensioning element changes de‐ pending on the engine temperature.
  • Page 47 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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-.
  • Page 48 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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.
  • Page 49 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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- –...

  • Page 50: Cylinder Head - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Cylinder head - remove and install Special tools and workshop equipment required ♦ Support -10-222A- ♦ Support -T10014- ♦ Tray -VAG 1306- ♦ Torque wrench - 5 to 50 Nm (enc.
  • Page 51 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Note Since the lifting eyes are located on the cylinder head, an addi‐ tional support should be fastened to the engine block for removing the cylinder head. – Fit Support bracket -10-222A- as shown and support the en‐...
  • Page 52 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 53: Compression - Check

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Compression - check Special tools and workshop equipment required ♦ U/J extension and socket, 10 mm -3220- ♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- ♦...
  • Page 54 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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 .

  • Page 55: Valve Command - Repair

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 56 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 9 - Valve internal spring ❑ Removing and installing: Cylinder head removed: with Compressor device -2037- mounted: ⇒ page 56 ❑ Install in the cylinder head before putting the bearing caps.

  • Page 57: Valve Seats - Rework

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Special tools and workshop equipment required ♦ Support -VW 387- ♦ Dial gauge Check with tappets removed and with bearing caps installed. Wear limit: max. 0.15 mm. Seal the contact surfaces of bearing caps 1 and 4 of camshaft, with Sealant -AMV 17400401- .
  • Page 58 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 59: Valve Guides - Check

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 2.1.3 Reworking escape valve seat =∅31.4 mm = 2.7 mm 45° = Valve seat angle Valve guides - check Special tools and workshop equipment required ♦ Support -VW 387- ♦...

  • Page 60: Valve Stem Seal - Replace

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Valve stem seal - replace Special tools and workshop equipment required ♦ Device -2036- ♦ Extractor -3047A- ♦ Fitter -3129- ♦ Lever -VW 541/1A- ♦ Supporting part -VW 541/5- 2.3.1...
  • Page 61 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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.

  • Page 62: Camshaft - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Camshaft - remove and install Special tools and workshop equipment required ♦ Blocking device -T10051- ♦ Extractor -T10052- ♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- ♦...
  • Page 63 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Loose hub fastening screw -1-. – Use Blocking device -T10051- . – Loosen hub securing screw about 2 turns. – Install Puller -T10052- and align it with holes in hub.
  • Page 64 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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°...

  • Page 65: Lubrication System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 17 – Lubrication system Lubrication system components - re‐ move and install Note When a significant number of metal chips and shavings ap‐ ♦ pear in the engine oil during engine repair due to crankshaft and rod bearing wear, the oil filter must be replaced and the oil gallery must be carefully cleaned.
  • Page 66 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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 67 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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 ❑...
  • Page 68 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 32 - 20 Nm 33 - Gear 34 - 8 Nm + 90° ❑ Replace after each removal. 35 - Chain tensioning element with tensioning plate. ❑ To remove, immobilise with Locking pin -T10060- .
  • Page 69 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 10 - Oil filter element 11 - Sealing plug, 10 Nm 12 - Gasket ❑ Replace. ❑ Install in the oil radiator groove. 13 - Oil radiator ❑ Check installation position.
  • Page 70 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 71 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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-.

  • Page 72: Crankcase - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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-.
  • Page 73 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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: ♦...

  • Page 74: Checking The Oil Pressure And The Oil Pressure Switch

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Checking the oil pressure and the oil pressure switch Special tools and workshop equipment required ♦ Oil pressure meter - V.A.G 1342- ♦ Test probe -VAG 1527B- ♦ Auxiliary measuring cable...
  • Page 75 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 76: Cooling System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 19 – Cooling system Cooling system components - re‐ move and install Note The cooling system is under pressure when the engine is hot. ♦ Thus, it is necessary to reduce the pressure before doing re‐...

  • Page 77: Cooling System Components In The Body

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Cooling system components in the body 1 - Radiator ❑ Remove and install ⇒ page 79 ❑ When replacing, change the complete coolant. 2 - Sealing ring ❑ Replace if damaged.

  • Page 78: Cooling System Components In The Engine

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Cooling system components in the engine 1 - Hose ❑ To heat exchanger. 2 - Connection 3 - 10 Nm 4 - Hose ❑ From the heat exchang‐ ❑ Hose connection dia‐...

  • Page 79: Cooling System Hose Connection Diagram

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ❑ Remove and install ⇒ page 80 17 - Sealing ring ❑ Check it is securely seated. ❑ Replace. 18 - Clip ❑ Check it is securely seated 19 - Coolant temperature sensor -G62- .

  • Page 80: Cooling System - Drain And Replenish

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Cooling system - drain and replenish Special tools and workshop equipment required ♦ Refractometer for cooling system fluid analysis - T10007- ♦ Tray -V.A.G 1306- ♦ Standart-type clamp pliers -...
  • Page 81 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Remove plug -arrow- for draining the cooling system. – , Also, disconnect the oil radiator hose -arrows-. Note Follow the recommendations for coolant disposal! 1. Cooling system components - remove and install...
  • Page 82 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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 ♦...

  • Page 83: Radiator - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.

  • Page 84: Water Pump - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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: –...
  • Page 85 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1.6.1 Removal Note Always replace seals and gaskets. – Drain the cooling system ⇒ page 76 – Remove Poly-V belt ⇒ page 14 – Remove timing belt ⇒ page 41 –...

  • Page 86: Thermostat - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Thermostat - remove and install Special tools and workshop equipment required ♦ Refractometer for cooling system fluid analysis - T10007- ♦ Tray -V.A.G 1306- ♦ Torque wrench - 5 to 50 Nm ( enc.
  • Page 87 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Loosen fastening screws -1- from connection flange -2- and remove connection flange -2- with thermostat -4-. – Rotate the thermostat -4- / 4 of turn (90 °) to left and remove it from connection flange -2-.

  • Page 88: Supply System - Fuel Tank, Fuel Pump

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 20 – Supply system - Fuel tank, fuel pump Fuel supply system components - re‐ move and install Note The hose connections are fastened by spring clamps or bra‐...
  • Page 89 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 8 - Fuel supply tube 9 - Spring-type clamp 10 - Fuel tank ❑ Support with Engine/gearbox jack -VAG 1383A- when removing. ❑ Remove and install ⇒ page 88 11 - 26 ±...
  • Page 90 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 To pressure relief valve. To gravity valve. Expansion tank. Vent hose (From the fuel tank). Anti-choke hose (From the fuel tank). Fuel pump installation position Flange mark shall be aligned with fuel tank mark -arrow-.

  • Page 91: Fuel Filter - Repair

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Fuel filter - repair 1 - Supply tube ❑ From the fuel tank. ❑ White or with white marking. ❑ Check that it is securely connected. 2 - Return pipe ❑...

  • Page 92: Safety Measures For Working On The Fuel Supply System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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: ♦...
  • Page 93 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ Torque wrench - 5 to 50 Nm ( enc. 1/2") -VAG 1331- ♦ Jack - Gearbox or engine + gearbox -VAG 1383A- ♦ Standart-type clamp pliers -VAS 5024A- ♦...
  • Page 94 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 WARNING ♦ The fuel and hoses in the fuel system may be very hot (risk of burns)! ♦ Fuel system is under pressure! ♦ Use protective gloves and eyewear when performing any repairs on the fuel system! –...

  • Page 95: Fuel Pump - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Fuel pump - remove and install Special tools and workshop equipment required ♦ Spanner -VW 5321/9- or Spanner -T10334- ♦ Torque wrench - 40 to 200 Nm ( enc. 1/2") -VAG 1332- 1.6.1...

  • Page 96: Fuel Meter Sensor - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Loosen the pump with Spanner -VW 5321/9 - or Spanner - T10334- . – Remove fuel pump and seal fuel tank opening. Note When the fuel pump is to be replaced, drain it before discarding.
  • Page 97 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ Portable multimeter -VAG 1526C- or Multimeter -V.A.G 1715- ♦ Auxiliary cable set -V.A.G 1594 A- ♦ Test probe -VAG 1527B- Test conditions • The fuses must be in order.

  • Page 98: Accelerator Mechanism - Repair

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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.

  • Page 99: Auxiliary Pump - Check

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1.10 Auxiliary pump - check Special tools and workshop equipment required ♦ Pressure test equipment -VAS 5187- ♦ Torque wrench - 5 to 50 Nm ( enc. 1/2") -VAG 1331- ♦...
  • Page 100 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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 .

  • Page 101: Auxiliary Pump - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1.11 Auxiliary pump - remove and install Special tools and workshop equipment required ♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331- ♦ Vacuum pump -VAG 1390- ♦...
  • Page 102 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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‐...
  • Page 103 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Install auxiliary pump and tighten upper securing bolts to 20 – Tighten lower securing bolts to 10 Nm. – Fit supply pipe -2- (white marking) to auxiliary pump supply connection and vacuum hose -1- from servo-assisted brake to the auxiliary pump -4-.
  • Page 104 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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‐...

  • Page 105: Overcharge - Turbo

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 21 – Overcharge - turbo Overcharge system with turbocharg‐ Safety measures WARNING During assembly work, especially within the engine compart‐ ment, due to the lack of space, bear in mind the following : ♦...
  • Page 106 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 107 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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/...

  • Page 108: Intake Air Cooling System (Intercooler) Components - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 21 - Oil supply tube ❑ From oil filter support. ❑ Before installing, check oil supply tube for continuity. ❑ Before installing, fill turbocharger with engine oil through the oil supply tube connection.
  • Page 109 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1 - Air ducts 2 - Intercooler 3 - 8 Nm 4 - Sealing ring ❑ Replace if damaged. 5 - Intake manifold pressure sensor -G71- with Intake mani‐...

  • Page 110: Supply System - Mechanical Injection (Diesel)

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 23 – Supply system - mechanical injection (diesel) Maintaining the direct injection Diesel system The direct injection diesel system command unit has a fault mem‐ ory. Before performing repairs, and for fault location, refer to the fault memory ⇒...

  • Page 111: Safety Measures

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 6 - Air mass meter -G70- 7 - Air filter 8 - Auxiliary pump ❑ Check ⇒ page 95 9 - Vacuum pump 10 - Connector ❑ For Pump / injector valve of cylinder 1 -N240- ... Pump / injector valve of cylinder 4 -N243- .

  • Page 112: Intake Manifold Valve - Repair

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ Carefully clean all the connections and surrounding areas be‐ fore disconnecting them. ♦ Place all the parts removed on clean surface and cover them. Do not use cloth that releases lint! ♦...

  • Page 113: Injectors - Repair

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Injectors - repair ♦ Follow cleanliness rules ⇒ page 88 ♦ Always replace retainers and sealing rings. WARNING Always replace self-locking nuts and screws subject to angular torque 1 - 20 Nm + 90°...
  • Page 114 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 ♦ Assembly sleeve -T10056- 1.6.1 Removal – Remove carefully old rings from injector. – Ensure that no burrs are formed on the ring seat in the oper‐ ation above.
  • Page 115 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Slide Assembly sleeve -T10056/2- to stop position on unit in‐ jector. – Slide intermediate ring carefully towards assembly sleeve and into injector seat. – Remove assembly sleeve. – Slide Assembly sleeve -T10056/3- to stop position on unit in‐...

  • Page 116: Injectors - Remove And Install

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Injectors - remove and install Special tools and workshop equipment required ♦ Support -VW 387- ♦ Multi-tooth Socket -3410- ♦ Special wrench, long reach -T10054- ♦ Extractor -T10055- ♦ Torque wrench - 5 to 50 Nm (enc.
  • Page 117 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Position the Puller -T10055- into the slot on the injector side instead of the tensioning block. – Pull the injector out of cylinder head seat with gentle taps.
  • Page 118 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – 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).

  • Page 119: Engine Command Unit

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Engine command unit Engine command unit - remove and in‐ stall – Before removing engine command unit, refer to the command unit ID and this respective code ⇒ page 115 2.1.1...

  • Page 120: Adjusting Functions And Components

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 121 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Select 01 systems with self-diagnosis – Select engine control – Select functions – Select function or component 2. Engine command unit...

  • Page 122: Exhaust System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 26 – Exhaust system 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‐...
  • Page 123 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 1 - Gasket ❑ Replace. 2 - Self-locking nut ❑ 25 Nm ❑ Replace after each re‐ moval. 3 - Support strap ❑ Replace if damaged. 4 - Front exhaust pipe with cat‐...

  • Page 124: Exhaust Gas Recirculation System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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- .

  • Page 125: Vacuum Hose Connection Diagram

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 Vacuum hose connection diagram Solenoid valve connections Turbocharger air filter hose. Turbocharger vacuum unit. Overcharge pressure connection in the turbocharger. BNM engine code - sealed. Air filter. Vacuum connection (in the non-return valve to servo brake ).

  • Page 126: Chamber Pre-Heating System

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 28 – Chamber pre-heating system Chamber pre-heating system - check Special tools and workshop equipment required ♦ Portable multimeter -VAG 1526C- ♦ Auxiliary measuring cable set -VAG 1594C- Test conditions: •...

  • Page 127: Checking Heating Plugs

    Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 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.
  • Page 128 Fox 2004 ➤ 3 - Cyl. diesel engine - Edition 02.2009 – Connect the Test probe -VAG 1527B- wire, using the Meas‐ urement auxiliary cable set -VAG 1594C- , to the battery positive (+) terminal. – Position the Test probe -VAG 1527B- on each heating plug, one-by-one.

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