VW Workshop Manual 3 Cyl Injection Engine BMD FOX 2004

Service
Workshop Manual
FOX 2004
3 - Cyl. injection engine
Engine ID BMD CHF
B
Edition 12.2009
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Service Department. Technical Information

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00 - Technical data
10 - Cylinders, engine block, support, protector
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13 - Crankshaft, pistons
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15 - Cylinder head, valve control mechanism

17 - Lubrication system
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19 - Cooling system
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20 - Supply system - tank, Fuel pump (pre-supply pump) G6
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24 - Supply system - fuel injection
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26 - Exhaust system
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28 - Ignition 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 BRA5R007520

FOX 2004
3 - Cyl. injection engine - Edition 12.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Cylinders, engine block, support, protector . . . . .ag. e.n A. G. ..Vo.lk.sw. a.g.en.A.G.do. . . . . . . . . . . . 3

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1 Engine - remove and install . . . . . . . . . . . . .by. V.o.l . . . . . . . . . . . . . . . . . . . . . o.t .gu. a. . . . . . . . 3
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1.1 Removal - indications . . . . . . . . . . . . . . o.ri.se. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.nt.ee. . . . . 4
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1.2 Additional notes and assembly works sin au vehicles with air conditioning. . . . . . . . . . . . . .r a.c . . 7
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1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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13 - Crankshaft, pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1 Engine - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.1 Part I - Operating Poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
spec
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1.2 Part II - Operating the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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1.3 Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Control box - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Engine block, seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.1 Crankshaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.2 Crankshaft seal (pulley side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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2.3 Crankshaft seal (flywheel side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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15 - Cylinder head, valve control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.1 Cylinder head - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.2 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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1.3 Distribution times - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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1.4 Roller chains - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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1.5 Distribution times - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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1.6 Compression - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2 Camshaft mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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2.1 Camshaft mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.2 Camshaft - check axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3 Valve seat - trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 Valve guides - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.5 Valve stem seal - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Lubrication system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Oil crankcase - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Oil pressure and Oil pressure switch F1 - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1 Cooling system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.1 Cooling system components on body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Cooling system components, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Cooling system hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4 Cooling system - drain and replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.5 Radiator - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Water pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
FOX 2004
20 - Supply system - tank, Fuel pump (pre-supply pump) G6 . . . . . . . . . . . . . . . . . . 62

1 Fuel supply system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Fuel supply system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Safety measures in fuel supply works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.4 Fuel pump (pre-supply pump) G6 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.5 Fuel level sensor G - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.6 Fuel reservoir - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.7 Fuel shut off in case of accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.8 Fuel pump (pre-supply pump) G6 - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.9 Supply system - drain the air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Activated charcoal filter system components - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.3 Reservoir ventilation - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3 Engine power electronic adjustment (electronic accelerator) . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Engine power electronic adjustment (electronic accelerator) . . . . . . . . . . . . . . . . . . . . . . . . 84
24 - Supply system - fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1 Injection system - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Fuel injection components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.3 Intake manifold - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.4 Fuel distributor with injection valves - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Air filter set - disassemble and assemble s wa.g.en. . . . . . . . . . . A
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1.6 Air filter set - remove and install se.d b. . . . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . . . . . 91
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1.7 Safety measures . . . . . . . .u.tho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ee. o.r . . . . . . . . . . . 92
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1.8 Cleaning rules . . . . . . . . s.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . 93
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1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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2 Check components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
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2.1 Injection valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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2.2 Residual pressure and fuel pressure regulator - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

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3 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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3.1 Engine control unit J623 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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3.2 Check and erase the fault memory in the Engine control unit J623 . . . . . . . . . . . . . . . . . . 102
3.3 Functions and components - adapt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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1 Exhaust system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.1 Exhaust manifold, catalyst and front exhaust pipe with intermediate muffler . . . . . . . . . . . . 106
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1.2 Rear muffler with supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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1 Ignition system - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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1.1 Ignition system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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1.2 Ignition coils with final power stages - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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1.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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1.4 Test data, Spark plugs Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
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ii Contents
FOX 2004
00 Technical data
1 Technical Data
Engine number page 1
1.1 Engine number

The engine number is comprised of nine digits (alphanumerical)
at most. The first part (max. of three identification letters) repre
sents the engine ID letters; the second part (six characters) is
the serial number. If more than 999,999 engines with the same
engine identification letters are produced, the first of the six digits
is replaced by a letter.
Engine number (engine identification letters and serial num
ber) is located on the engine block front surface, next to the
gearbox.
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Additionally, there is sticker -arrow- with the engine identification

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1.2 Engine features

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Identification letters BMD CHFB
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Production 05.04 03.09
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1198 1198
Power cv (kW)/rpm 55(40)/4750 55(40)/4750
Torque Nm (mkgf)/rpm 106(10,9)/3000 106(10,9)/3000
Diameter mm 76,5 76,5
Stroke mm 86,9 86,9
Compression rate 10,3 10,3
Valves per cylinder 2 2
Octane rating at least 95 lead-free 1) 95 lead-free 1)
Injection, ignition Simos 3PG2) Simos 9.1
Knock control 1 knock sensor 1 knock sensor
Lambda adjustment 2 probes 2 probes
Catalyst yes yes
Recirculation of exhaust gases no no
1. Technical Data 1
FOX 2004
Identification letters BMD CHFB

Overcharge no no
1) in exceptional cases, octane rating of at least 91, but with reduced power.
2) Simons 3 PG installed up to May/2006, Simons 9.1 stared as of June/2006.
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2 Rep. Gr.00 - Technical data

FOX 2004
10 Cylinders, engine block, support, protector

1 Engine - remove and install
Removal page 4 .
Additional notes and mounting works in vehicles with air condi
tioning page 7 .
Installing page 7 .
Tightening torque page 8 .
Special tools and workshop

equipment required
Hanger or 2024A -VW 055-
Hydraulic moving hoist -
500Kg or VAS 6100 -EQ
7025-
Rotary stand for engine and
transmission -VAS 6095-
Torque wrench - 5 to 50 Nm
(enc. 1/2") -VAG 1331-
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1. Engine - remove and install
FOX 2004
Torque wrench - 40 to 200

Nm (enc. 1/2") -VAG 1332-
Container -VAS 6208-
VW 5162 or Standart-type
clamp pliers -VAS 5024A-
Grease -G 000 100-
Clamp
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1.1 Removal - indications h eo
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Disconnect the Battery -A- earth strap for carrying out the oper
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The engine is removed from the front along with the transmis
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With the ignition switched off, disconnect the Battery -A- earth
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strap.
All clamps loosened or cut during engine removal must be
nform
ercia
placed in the same position again during engine installation.

m
Remove air filter set page 91 .

a
com
tion in
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Cop py
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Rep. Gr.10 - Cylinders, engine block, support, protector
agen
Prote AG.
FOX 2004
Remove the Battery -A- and the Battery support -A- -arrows-
Electrical equipment; Rep. Gr. 27 ; Starter, generator,
battery .
Open and close the coolant reservoir lid to depressurize the
cooling system.
Release/separate all transmission electric cables of the Gen
erator (Alternator) -C- and Starter -B- .
Loosen/separate all of the remaining necessary engine elec
tric cables.
G. Volkswagen AG d
WARNING
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A
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not
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Fuel supplyhoris tube is under pressure! Wear protective ntegoggles
eo
and gloves
aut
to prevent injuries and avoid contact with ther a skin.
c
Before loosening tube junctions, place a cloth around them.
ss
ce
le
Eliminate pressure, pulling the tube carefully.

un
pt
an
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itte
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rm
ab
pe
ility
ot
Loosen the fuel supply pipes -1- (press the unlock key).
wit
, is n
h re
Remove the Electromagnetic valve for activated charcoal filter
hole
spec
-N80- hose on the intake manifold.
es, in part or in w
t to the co
Close the hoses so as to prevent impurities from entering the
fuel system.
Follow cleaning rules page 65 . rrectness of i
l purpos
Remove vacuum and vent hoses from the engine.

Disengage the connectors from the Radiator fan thermal
nform
ercia
switch -F18- and from the Radiator fan -V7- .

m
Remove fastening screw from front exhaust tube support strap

a
com
tio
in the transmission.
n in
r
te o
thi
Loosen front exhaust tube from catalytic converter

s
iva
do
page 106 .
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cum
fo
en
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t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
1. Engine - remove and install 5

FOX 2004
Remove transmission pendulum support -arrows-.

Remove clutch actuator hydraulic cylinder: Automatic / me
chanical transmission ; Rep. Gr. 30 ; Clutch - command
system .
Remove transmission gearshift command: Automatic/me
chanical transmission; Rep. Gr. 34 ; Drive, housing .
en AG. V
olkswagen AG
wag does
Drain the cooling system page 56 . olks not
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ris
Remove engine cooling system hoses tho with VW 5162 or Stand eo
au
ard type clamp pliers - VAS 5024A-
ss .
ra
c
ce
le
Remove the Poly-V belt page 13 .

un
pt
an
d
itte
y li
Put front panel in the work position: Body - Repair ; Rep.
rm
ab
Gr. 50 ; Body - Front part .
pe
ility
ot
wit
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Vehicles with air conditioning
h re
hole
Remove air conditioning compressor: Aeration system;
spec
es, in part or in w
Rep. Gr. 87 ; Air conditioning and anchor to the body with a
t to the co
wire.
Observe additional indications and assembly works
page 7
rrectness of i
Continued for all vehicles.
l purpos
Remove drive shafts, on the left and right side of the trans
mission, and fasten them on top: Chassis; Rep. Gr. 40 ;
nform
ercia
Front suspension .
m
a
com
tion in
Install the Hanger or VW 055 -2024A- and lift it with a hydraulic
r
te o
thi
hoister.
s
iva
do
r
rp
c
Pulley side: position 1 of the vertical rod. Orifice on the sustaining
um
fo
bar in position 1. en
ng
t.
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op
Steering wheel side: position 2 of the vertical rod. Orifice on the
C py
t. rig
gh
sustaining bar in position 5.
ht
pyri by
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cted agen
Prote AG.
Caution
Use safety pins on fitting hooks and pins so as to prevent dam

ages to the engine and vehicle.
Note
Positions numbered 1...8 on suspension bar face the pulley

side.
The holes in the supports are counted from the hook.
6 Rep. Gr.10 - Cylinders, engine block, support, protector

FOX 2004
Remove power-drive group support, engine-arrows-.
Remove power-drive group support, transmission -arrows-.

Remove the assembly from the front. For that, move gthe
en Aas
G. Volkswagen AG d
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sembly and lift it little by little until passing it over
y Volkthe front not
gu
panel. ris
ed b ara
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s au ac
s
Note
ce
e
nl
pt
du
an
itte
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The assembly must be guided carefully when lifted to prevent
erm
ab
damages to the body.
ility
ot p
wit
, is n
h re
For removal works, the engine must be anchored to the Rotary
hole
spec
stand for engine and transmission -VAS 6095- .
es, in part or in w
t to the co
Remove engine flange transmission.
Fasten the engine to the Rotary stand for engine and trans
mission -VAS 6095- .
rrectness of i
l purpos
1.2 Additional notes and assembly works in

vehicles with air conditioning.
nform
mercia
at
om
io
Note
n
c
in t
or
his
ate
To avoid damage to the condenser and cooling gas hoses, do not

do
priv
kink, twist nor overstretch the hoses.

um
for
en
ng
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op
To be able to remove and install the engine without opening the C py
t. rig
cooling gas circuit:
gh ht
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Remove cooling gas hose clamps. cted agen
Prote AG.

Remove air conditioning compressor from support with cooling
gas pipes connected: Heating - ventilation ; Rep. Gr. 87 ;
Air conditioning .
1.3 Installation
Installation is carried out in removal reversed order, considering
the following:
Check clutch bearing for wear and replace it, if necessary.
Slightly lubricate clutch bearing, guide roller bearing and pri
mary shaft with Grease - G 000 100- .
Check if guides for engine coupling and transmission are
placed on the engine block and, if necessary, install them.
When lowering the subframe, make sure it will not hit the drive
shafts.

FOX 2004
Adjust engine supports with no tension.
Note
Tightening torque for the assembly page 8 .
Install drive shaft: Chassis; Rep. Gr. 40 ; Front suspension .

Install air conditioning compressor: Heating - ventilation ;
Rep. Gr. 87 ; Air conditioning .
Electrical connections and installation: Current flow dia
grams, Electrical fault finding and Fitting locations.
Install Poly-V belt page 13 .
Install clutch actuator hydraulic cylinder: Automatic/me
chanical transmission; Rep. Gr. 30 ; Clutch - control system .
Install transmission gearshift command Automatic / me
chanical transmission; Rep. Gr. 34 ; Drive, housing .
Fill cooling system page 56 .
Install air filter set page 91 .
Adapt Engine control unit -J623- to the Accelerator butterfly
valve control unit -J338- Vehicle diagnosis, testing and in
formation system VAS 5051.
Perform test drive and check fault memory
gen AG
.
Vopage
lkswag102
en AG.
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1.4 Tightening torques ed
by gu
ara
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Location au Tightening tor ra
c
ss
que
ce
le
un
pt
Screws and nuts M6 10 Nm

an
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rm
M8 20 Nm
ab
pe
ility
M 10 45 Nm
ot
wit
, is n
h re
M 12 60 Nm
hole
spec
Exhaust tube to manifold 40 Nm

es, in part or in w
t to the co
Support for the power-drive group

rrectness of i
Note
l purpos
The power-drive group support fastening screws are expansion

screws and must be mandatorily replaced.
nform
mercia
a
com
tion in
WARNING
r
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thi
s
iva
do
Always replace self-locking nuts and screws subject to angular

r
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torque
fo
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t.
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Cop py
t. rig
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cted agen
Prote AG.
8 Rep. Gr.10 - Cylinders, engine block, support, protector

AG. Volkswagen AG d
agen oes
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by Vol
gu
ara
FOX 2004
d
rise 3 - Cyl. injection engine
nte - Edition 12.2009
tho eo
s au ra
c
Power-drive group support, engine s
ce
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nl
pt
du
A = 20 Nm + 90
an
itte
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erm
ab
B = 30 Nm +90
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Power-drive group support, transmission
nform
ercia
A = 40 Nm + 90
m
at
B = 50 Nm +90
om
ion
c
in t
r
C = 50 Nm +90
o
his
ate
do
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cum
for
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Cop py
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cted agen
Prote AG.
Pendular support
A = 30 Nm + 90
B = 40 Nm +90

FOX 2004
13 Crankshaft, pistons
1 Engine - disassemble and assemble
For disassembling works, the engine must be fastened to the
Support -VW 540- or Rotary stand for engine and transmission -
VAS 6095- .
Part I - Operating the belt page 11 .
Part II - Operating the chain page 11 .
Remove and install Poly-V belt page 13 .
Remove and install control box page 15 .
Caution agen
AG. Volkswagen AG d
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Crankshaft cannot be removed. Simply loosen crankshaft rised
nte
bearing cover bolts for the engine block bearing shellsaunot
o
th to eo
ra
be deformed. Such deformation reduces bearing shellss clear
s c
ance. Even if bearing shells are not replaced, there can be
ce
e
nl
pt
du
damages due to change in the clearance.
an
itte
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erm
ab
If bearing cover bolts are loosened, the entire engine block with
ility
ot p
the crankshaft will have to be replaced.
wit
, is n
h re
The workshop does not have the necessary means to measure
hole
the crankshaft radial clearance.
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
torque
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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Cop py
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cted agen
Prote AG.
10 Rep. Gr.13 - Crankshaft, pistons

FOX 2004
1.1 Part I - Operating Poly-V belt
1 - 20 Nm
2 - Pulley
For water pump.
3 - Cover
4 - Poly-V belt tensioning pul
ley
5 - 20 Nm + 90
Replace after each re
moval.
6 - Alternator
7 - Return pulley
8 - Washer
9 - Pulley
From the crankshaft.
10 - 90 Nm + 90
Replace after each ren AG. Volkswagen AG do
moval. wage es n
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11 - Guide bushing
ris
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12 - 25 Nm
ss
a ra
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13 - Guide bushing
nl
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du
an
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14 - Spacer sleeve
erm
ab
ility
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15 - Poly-V belt
wit
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Mark rotation direction

h re
hole
before removal.
spec
es, in part or in w
Remove and install

t to the co
Poly-V belt
page 13 .
rrectness of i
l purpos
1.2 Part II - Operating the chain

nform
mercia
WARNING
at
om
ion
c
in t
r

o
his
te
torque
a
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
1. Engine - disassemble and assemble 11

FOX 2004
1 - Cylinder head cover

Sealing surface cannot
be ground.
With integrated cam
shaft bearings.
Remove residues from
the old Sealing putty for
engines -AMV 188 001
02- .
Before installation, ap
ply a coat of Sealing put
ty for engines -AMV 188
001 02- .
For installation, put it in
the vertical position,
from up to down, with
the adjusting pins into
the cylinder head holes.
2 - Engine block
2 parts.
The screws cannot be
loosened.
3 - Gear
4 - Gear
From balancing shaft.
Fastening screw cannot
be loosened.
5 - Chain stretcher with ten wage
es n
sioning chute yV
olks ot g
ua
d b
From roller chain o
ir se
ran
tee
Item 10 (page 12) . auth or
ac
ss
6 - Oil pump
ce
le
un
pt
Replace only the complete set.

an
d
itte
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rm
ab
7 - Sliding chute
pe
ility
ot
From roller chain Item 33 (page 13) .

wit
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h re
8 - Gear
hole
spec

es, in part or in w
t to the co
9 - Gear
From oil pump activation.
rrectness of i
10 - Roller chain
l purpos
Mark rotation direction before removal (installation positions).

11 - Gear
nform
ercia
From oil pump.

m
a
com
After installation, adjust distribution times page 32 .

ion in
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te o
12 - Crankcase
thi
s
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do
Remove and install in engines with liquid joint page 48 .

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Clean the Engine silicone sealant -D 176 404 A2- from the surface before installing.
en
ng
t.
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Install with Engine silicone sealant -D 176 404 A2- . Cop py
t. rig
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pyri by
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cted agen
Prote AG.

FOX 2004
13 - 15 Nm
14 - 8 Nm
15 - Cover
16 - 20 Nm + 90
Replace after each removal.
17 - Crankshaft pulley
18 - 90 Nm + 90
Replace after each removal..
Fit lubricated.
Immobilise crankshaft pulley with the Spanner -3415- .
The additional angle torque can be measured with a spanner, e.g. Hazet 6690.
19 - Supporting bushing
20 - 25 Nm
21 - 45 Nm
22 - 10 Nm
23 - 10 Nm
24 - To intake manifold AG. Volkswagen AG d
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25 - Oil separator d b ara
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With depression valve. autho eo
ra
ss c
26 - Sealing ring
ce
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nl
pt
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Replace if damaged
an
itte
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erm
ab
27 - Control box
ility
ot p
Install with Engine silicone sealant -D 176 404 A2- .

wit
, is n
h re
For better alignment in assembly, install two vertical bolts -M6x75- into the cylinder head and engine
hole
spec
block.
es, in part or in w
For better alignment of the control box, install oil crankcase with two bolts.
t to the co
28 - Cover
rrectness of i
29 - 20 Nm + 90
l purpos
30 - Tensioning chute
nf
ercia
31 - Chain stretcher
orm
m
atio
32 - 15 Nm
om
n in
or c
33 - Roller chain
thi
te
sd
iva
34 - Gear
o
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m
f
From Camshaft
en
ng
t.
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op
Immobilise the gear with the Special wrench -3036 - . C py
t. rig
gh ht
yri
35 - Guide pin
p by
co Vo
by lksw
cted
Tightening torque: 20 Nm
agen
Prote AG.
1.3 Poly-V belt - remove and install

Special tools and workshop equipment required

AG. Volkswagen AG d
agen oes
olksw not
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FOX 2004 rise
d b ara
nte
3 - Cyl. injection engine - Edition a12.2009
ut
ho eo
ra
ss c
ce
le
Hexagonal wrench -3449-
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
Operation sequence
nform
ercia
Mark the Poly-V belt turning direction.

m
a
com
tion in
Move tensioning element in the arrow direction, until the hole
r
te o
thi
is visible. Retain tensioning element with an Hexagonal
s
iva
do
wrench -3449- .
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.
Move the tensioning element towards -arrow- with socket and

spanner. Secure the tensioning element with a Hexagonal
wrench -3449- .
Remove or install Poly-V belt .
Note
When installing Poly-V belt, ensure the proper seating of the belt
on the pulleys.
Poly-V belt travel
Belt operation without ar conditioning compressor

1 - Water pump pulley
2 - Tensioning pulley
3 - Generator (Alternator) -C- pulley
4 - Poly-V belt

FOX 2004
Belt operation with ar conditioning compressor

1 - Water pump pulley
2 - Tensioning pulley
3 - Generator (Alternator) -C- pulley
4 - Pulley
5 - Air conditioning compressor pulley
6 - Poly-V belt
The rest of the installation is carried out in removal reverse order.
1.4 Control box - remove

Volkswa
and install
AG. gen AG
agen does
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V gu
by
Special tools andrisworkshop
ed
ara
nte
equipment required
tho eo
s au ra
c
Support or 10-222A -VW
s
ce
e
nl
061-
pt
du
an
itte
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Hooks -10-222A/10-
erm
ab
ility
ot p
Wrench -3415-
wit
, is n
h re
Pins -3415/1-
hole
Torque wrench - 5 to 50 Nm spec

es, in part or in w
(enc. 1/2") -VAG 1331- t to the co

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

FOX 2004
Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
ss c
ce
le
un
pt
an
d
1.4.1 Removal
itte
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rm
ab
pe
ility
Remove the front right wheel case protector: Body - Exter
ot
wit
nal assembly repairs; Rep. Gr. 66 ; External equipment .
, is n
h re
hole
Mark the Poly-V belt operating direction and remove it
spec
page 13 .
es, in part or in w
t to the co
Remove air conditioning compressor from support with pipes
connected: Heating - ventilation ; Rep. Gr. 87 ; Air condi
tioning .
rrectness of i
Remove Generator (Alternator) -C- .
l purpos
Install Support -10-222 A- with Rack -10 - 222 A /1- , as illus

trated, and install on lifting eye-arrow-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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.
Pre-tension the engine slightly and loosen fastening bolts

-arrows-.
Remove oil crankcase page 48 .

FOX 2004
Remove the fastening bolts from the crankshaft pulley. Immo

bilise the pulley with the Spanner -3415- and -3415/1- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
Remove fastening bolts
ss a
from control box and bolts designated c
by the -arrows-.
ce
le
un
pt
an
d
Remove control box.

itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Ensure that the crankshaft support pin remains on sealing flange.
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
1.4.2 Installation
rp
cum
fo
en
ng
t.
yi
Clean sealing surfaces thoroughly. They must be free from oil
Co
Cop py
and grease.
t. rig
gh ht
pyri by
Vo
o
Seat the new gasket on adjusting pin. by c lksw
cted agen
Prote AG.
To facilitate alignement, install two Bolts -M6x80- on cylinder
head and engine block.
Install control box and crankshaft support, simultaneously on
threaded-end pins, adjusting pins and crankshaft crankpin.
Tighten fastening bolts on control box evenly and in a cross
pattern.
Make sure the camshaft housing is not gripped.
Tightening torque:
Bolt M 6 to 10 Nm.
Bolt M 10 to 50 Nm.
Resume the installation in the removal reverse order.

FOX 2004
2 Engine block, seals

Remove and Install page 18 lkswage es n
o ot g
byV ua
Replace crankshaft seal - pulley side page 19 ir se
d ran
tee
tho
u or
Replace crankshaft seal - engine flywheel side page 21 ss
a ac
ce
le
un
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility
ot
wit
torque
, is n
h re
hole
spec
es, in part or in w
2.1 Crankshaft seals
t to the co
rrectness of i
1 - 90 Nm + 90
l purpos
moval..
Fit lubricated.
nform
ercia
Immobilise crankshaft
m
pulley with the Spanner
a
com
tio
-3415- .
n in
r
te o
thi
The additional angle tor
s
iva
que can be measured
do
r
rp
c
with a spanner, e.g. Ha
um
fo
en
zet 6690.
ng
t.
yi Co
op py
2 - Washer t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Remove and install
AG.
Poly-V belt page 13 .

4 - Support sleeve
5 - Crankshaft seal (pulley
side)
Replace page 19 .
6 - Engine block
7 - 60 Nm + 90
moval.
8 - Flywheel
9 - Intermediate plate
Must seat on adjusting
guide.
Do not damage/twist
while removing and in
stalling
10 - Crankshaft seal (flywheel
side)
Replace page 21 .

AG. Volkswagen AG d FOX 2004
agen
Volksw 3 - oCyl.
es n injection engine
ot g - Edition 12.2009
d by ua
ran
e
ris tee
2.2 Crankshaft seal (pulley side) - replace autho
or
ac
ss
ce
e
nl
pt
du
an
itte
y li
equipment required
erm
ab
ility
Puller -3203- ot p
wit
, is n
h re
hole
Nm (enc. 1/2") -VAG 1332-
spec
es, in part or in w
t to the co
Assembly device -T10117-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.2.1 Removal
Remove the fastening bolts from the crankshaft pulley. Immo
bilise crankshaft pulley with the Spanner -3415- and -3415/1- .
Remove centre bolt and crankshaft pulley.
Turn inner part of Puller -2085- three turns (around 5 mm) from
external part and lock with knurled bolt.
2. Engine block, seals 19

FOX 2004
Lubricate puller threaded head, seat it and thread it as firmly

as possible onto the seal.
Loosen the knurled bolt and turn the inner part against the
crankshaft until the seal is extracted.
2.2.2 Installation
Seat Sleeve -T 10117/2- on trunnion and move seal.
Remove Sleeve -T 10117/2- . 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
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Press seal with Pressure sleeve -T10117- up to control box
es, in part or in w
t to the co
stop, through uniform tappings.
rrectness of i
l purpos
nf
ercia
orm
m
atio
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FOX 2004
2.3 Crankshaft seal (flywheel side) - replace

equipment required
Extraction hook -2086-
(enc. 1/2") -VAG 1331-
Nm (enc. 1/2") -VAG 1332-
Insertion device -T10122-
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Note
es, in part or in w
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In order to better represent the operation sequences, tthey are

carried out with the engine removed.
rrectness of i
The operation sequences with both engine and transmission

removed are identical.
l purpos
2.3.1 Removal
nf
ercia
orm
m
Remove clutch assembly and engine flywheel.

atio
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2. Engine block, seals 21

FOX 2004
Remove seal with the Extraction hook -2086 - .
2.3.2 Installation yV
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Note ss
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Only remove support ring from seal right before its installation.
an
itte
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Join Assembly bearing shells -T 10122/1- and -T10122/2- .
ot p
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Move the seal -A- on Assembly bearing shell -T 10122/2- up
h re
hole
to the stop.
spec
es, in part or in w
Separate both assembly bearing shells.
t to the co
rrectness of i
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ion
c
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or
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do
priv
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for
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Prote AG.
Install Assembly bearing shell -T 10122/2- with seal on crank
shaft flange.
Press the seal with the Pressure bearing shell -T 10122/3- to
the stop.

FOX 2004
15 Cylinder head, valve control mechanism

1 Cylinder head
Note
When assembling a new cylinder head, it is necessary to lu

bricate with oil all stop surfaces between supporting elements,
roller rockers and camshaft eccentrics, before installing cylin
der head cover.
Plastic holders supplied for protecting open valves can only
be removed immediately before installing the cylinder head.
When you replace engine cylinder head, it is necessary to re
place cooling system liquid.
Remove and install intake manifold and injection valves
page 89 .
Cylinder head - remove and install page 25 .

Distribution times - check page 28 .
Roller chains - remove and install page 30 .
Distribution times - adjust page 32 .
Compression - check page 35 .
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1. Cylinder head 23
FOX 2004
1.1 Cylinder head - disassemble and assemble

be ground.
With integrated cam
shaft bearings.
old gasket.
Before installation, ap
ply a coat of Sealing put
ty for engines -AMV 188
001 02- .
the cylinder head holes.
2 - Sealing
Replace if damaged.
3 - Oil filler cap
4 - 20 Nm
5 - Lifting eye
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6 - Engine cylinder head screw yV
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Observe installation
ss
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structions and se
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un
quence for loosening

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and tightening
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page 25 .
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7 - From air filter set

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8 - Vacuum tube
spec
9 - Hall Sensor -G40-

t to the co
10 - 10 Nm
11 - Sealing ring
rrectne
Replace if damaged.
ss
12 - 10 Nm
o
cial p
f in
13 - Support
form
mer
For harnesses.
atio
om
n
c
14 - Oil pressure switch - F1- 0.3...0.6 bar, 25 Nm

i
or
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Check page 50 .
t
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15 - Sealing
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16 - Cylinder head sealing gasket t. Cop py
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Metallic gasket.
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Replace.
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After replacement, replace the cooling system fluid.
17 - Guide bolts
Tightening torque: 20 Nm
18 - Lifting eye
24 Rep. Gr.15 - Cylinder head, valve control mechanism

FOX 2004
AG. Volkswagen AG d
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1.2 Cylinder head - remove and install
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Special tools
s and workshop
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equipment required
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an
d
itte
Guides -3450-
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Support -T10358-
ility
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(enc. 1/2") -VAG 1331-
spec
"Torque wrench - 40 to 200
t to the co
Nm (enc. 1/2")" - VAG
1332-
rrectne
Support or VW 061
-10-222A-
ss o
cial p
f inform
mer
atio
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c
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The engine must be warm, at most.
1.2.1 Removal
Dismount the engine cover by pulling on the places marked
with -arrows-.
Install Support or VW 061 -10-222A- , as illustrated, and install
on lifting eye-arrow-.
Remove control box page 15 .
Remove water pump pulley.
1. Cylinder head 25
FOX 2004
Pull out the intake air duct of the air filter-arrow-.
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
Engage the first gear so that the fastening element of the gear
selection cable -1- allows access to the transmission fastening
l purpos
nut -2- and battery earth strap.
nform
mercia
a
com
tion in
r
te o
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Loosen the transmission fastening nut and battery earth strap
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and install the Support -T10358- , as illustrated. Prote AG.
Engage the hooks on the Support or VW 061 -10-222A - to the

Support -T10358- , as illustrated.
Turn the spindle until the hooks are subjecto to a slight tension.
Disengage hook -1-from the left lifting eyelet and move the left
spindle on the Support or VW 061 -10-222A- .
Remove intake manifold page 89 .
Remove the roller chains page 30 .
Remove the engine cylinder head cover.
Remove entire fuel distributor, with all injection valves, from
the engine cylinder head.
Disconnect all the other connection tubes of the cooling, vac
uum and intake systems from the engine cylinder head.
Loosen front exhaust pipe from exhaust manifold.

FOX 2004
Loosen and remove screws from the engine cylinder head ac

cording to the sequence indicated.
Remove engine cylinder head carefully.
1.2.2 Installation agen

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Only remove the new cylinder head sealing gasket from the
ce
le
un
pt
package immediately before installation.
an
d
itte
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Handle the new gasket as carefully as possible. Damages
ab
pe
ility
cause leaks.
ot
wit
, is n
h re
hole
Place clean cloths on the cylinders so as to prevent polishing
spec
impurities and residues from entering the cylinders and pis
es, in part or in w
tons.
t to the co
Prevent polishing impurities and residues from entering cool
ing system.
rrectness of i
Carefully clean engine cylinder head and engine block sealing
l purpos
surfaces. Make sure no sores or burrs are produced (when

using sandpaper, the grain shall not be lower than 100).
nform
ercia
Carefully remove polishing and sand paper residues as well

as the cloths.
m
a
com
tion in
Place cylinder 1 piston in TDC and quickly return crankshaft.
r
te o
thi
s
Install new cylinder head gasket on centering guides-A-. In
iva
do
r
scription (part number) -B- must be visible.

rp
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Install engine cylinder head, install the 8 bolts manually.

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1. Cylinder head 27
FOX 2004
Tighten engine cylinder head bolts in the indicated tightening

sequence.
Tighten screws to 30 Nm.
Then, tighten the bolts at 90 with a hard spanner.
Then, tighten 90 further.
Note
When turning the camshaft, the crankshaft cannot be in TDC.

Risk of damages to the valves/pistons.
Adjust distribution times page 28 .

The remaining assembly steps are made by inverting the dis
assembly sequence, paying attention to the following:
Check engine cylinder head for bending.

Max. permissible bending: 0.05 mm
1.3 Distribution times - check

AG. Volkswagen AG d
Fastening pins -T10120- agen oes
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Rep. Gr.15 - Cylinder head, valve control mechanism Prote
cted AG.
agen
FOX 2004
Fastening pins -T10121-
Test sequence
Remove Hall Sensor -G40- -arrow-.
Remove Engine speed sensor -G28- -arrow-.
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Turn crankshaft by the pulley fastening bolt in the engine

wit
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speed direction, until the camshaft groove is visible in the hole

h re
hole
designated to the Hall Sensor -G40- .

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
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iva
do
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Cop py
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1. Cylinder head 29
FOX 2004
The Pin -T10120- should fit into the camshaft easily.
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Lock crankshaft by fitting the Pin -T10121- into flywheel hole.
h re
hole
spec
es, in part or in w
Note
t to the co
If the Pin -T10121- does not fit easily, remove the Pin -T10120-
from camshaft. Turn crankshaft in the engine speed direction
rrectness of i
(360) and repeat the operation.
l purpos
If it is not possible to insert both fastening pins:
nform
ercia
Synchronize distribution times page 32 .

m
at
om
If it is possible to insert both fastening pins:
ion
c
in t
or
Remove both fastening pins from the holes and install both
his
ate
sensors again.
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1.4 Roller chains - remove and install

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Special tools and workshop equipment required cted agen
Prote AG.
Wrench -T10172-
Special wrench -3036-

AG. Volkswagen AG d
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olksw not FOX 2004
byV gu
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nte 3 - Cyl. injection engine - Edition 12.2009
ed
ris
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1.4.1 Removal
ss c
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nl
pt
du
an
Remove control box page 15 .
itte
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erm
ab
Fasten camshaft and crankshaft page 28 .
ility
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Remove torsion spring -1- with a screwdriver from threaded-
h re
end bolt.
hole
spec
es, in part or in w
Remove fastening bolt -2- and remove chain stretcher.
t to the co
Loosen fastening bolt -3-. To immobilise the gear, use the
Spanner -T10172- .
rrectness of i
Remove oil pump gear, roller chain and primary gear as a set.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Press tensioning chute manually in the -arrow direction- and

f
en
ng
t.
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lock chain stretcher with the Pin -T40011-
Co
Cop py
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Prote AG.
Loosen fastening screw. To do so, use the Special spanner

-3036- .
Remove tensioning chute and sliding chute from guide pins by
pulling them forwards.
Remove roller chains from the gears.
1.4.2 Installation
Run roller chain on crankshaft gear and camshaft gear.
Push tensioning chute and sliding chute forwards on the guide
pins.
Install camshaft gear with a new fastening bolt.
Tighten fastening bolts to 20 Nm + 90.
To do so, use the Special spanner -3036- .
Put the oil pump roller chain together with the two chain gears.
Screw oil pump gear with the new fastening bolt.
1. Cylinder head 31
FOX 2004
3 - Cyl. injection engine - Edition 12.2009 AG. Volkswagen AG d
agen oes
olksw not
V gu
Tighten fastening bolts-3- to 20 Nm + 90 ed by ara
nte
ris
o eo
Assemble oil pump activation chainaustretcher.
th
ra
ss c
Tightening torque -2- for the chain stretcher fastening bolt: 15 Nm
ce
e
nl
pt
du
an
To do so, use the Spanner -T10172- .
itte
y li
erm
ab
Install the torsion spring -1- with a screwdriver on the threa
ility
ded-end bolt. ot p
wit
, is n
h re
Adjust distribution times page 32 .
hole
spec
es, in part or in w
Install control box page 15 .
t to the co
rrectness of i
1.5 Distribution times - adjust
l purpos
nform
ercia
equipment required
m
at
om
io
Nm (enc. 1/2") -VAG 1332-
n
c
in t
or
his
e
at
do
riv
(enc. 1/2") -VAG 1331-

p
cum
for
en
g
Standart-type clamp pliers -

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t.
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VW 5162- or Standart-type Cop py
t. rig
clamp pliers -VAS 5024A- opyri
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Vo
ht
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Prote AG.
Wrench -3415-
Pins -3415/1-

FOX 2004
Operation sequence
Install the Support -VW 061- or Support -10-222A- with Hooks
- 10-222A/10- , as indicated.
Remove power-drive group support, engine-arrows-.

Remove or disconnect the following components:
Water pump pulley
Tensioning element pulley
Tensioning roll
Generator (Alternator) -C-
Air conditioning compressor
Crankshaft pulley
Oil dipstick agen
AG. Volkswagen AG d
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Crankcase d by gu
ara
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Control box chain
auth
drive ra
ss c
Install crankshaft pulley fastening bolt up to crankshaft stop.
ce
e
nl
pt
du
an
itte
y li
Turn crankshaft by the pulley fastening bolt in the engine

erm
ab
speed direction, until the camshaft groove is visible in the hole

ility
ot p
designated to the Hall Sensor -G40- .

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
The Pin -T10120- should fit into the camshaft easily.

m
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
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Prote AG.
1. Cylinder head 33
FOX 2004
Loosen the bolt fastening the camshaft gear (use a Special

wrench - 3036- ) .
Turn crankshaft by the pulley fastening bolt in the engine ro

tation direction until it is possible to insert the Pin -T10121- into
engine flywheel.
Tighten new bolt fastening the -2- camshaft gear-1- to 20 Nm

(use the Special wrench -3036- ).
Finally, turn the bolt 90 further with a hard spanner.
Remove two fastening pins from camshaft and engine fly
wheel.
Give the crankshaft two turns in engine rotation direction and AG. Volkswagen AG d
check distribution times again page 28 . olksw
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not
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Resume the installation in the removal reverse order. rised ara
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pe
ility
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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
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t.
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Cop py
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Prote AG.

FOX 2004
lkswage es n 3 - Cyl. injection engine - Edition 12.2009
o ot g
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1.6 Compression - check
autho eo
ra
ss c
ce
le
un
pt
an
d
itte
equipment required
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erm
ab
ility
Spark plug wrench -3122B-
ot p
wit
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h re
ole,
(enc. 1/2") -VAG 1331-
spec
Cylinder compression
t to the co
gauge - petrol/alcohol -
VAG 1763-
rrectne
Puller -T10094-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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Cop py
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Prote AG.
Test conditions
Engine oil temperature must be at least 30C.
1. Cylinder head 35
FOX 2004
Operation sequence
Disengage 4-pole connectors from Ignition coil 1 with final
power stage -N70- , Ignition coil 2 with final power stage -
N127- and Ignition coil 3 with final power stage -N291-
-arrows-.
Remove all ignition coils with the Puller -T10094- .
Remove Spark plugs -Q- with Spark plug wrench -3122B- .
Remove fuse 44 from injection valves.
Check compression with the Cylinder compression meter -
gasoline/alcohol -VAG 1763- .
Note
How to handle the testing device is described in the respective

operation instructions.
Operate starting motor until the testing device does not indi
cate any increase in pressure.
Compression value:
Engine prefix BMD/CHFB
Cylinder compression bar 10.0 to 15.0
Wear limit bar 7,0
Maximum compression differ bar 3,00
ence between cylinders AG. Volkswagen AG d
agen oes
olksw not
Install Spark plugs -Q- with Spark plug wrench -3122B-edand by
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ara
tighten to 30 Nm. horis nte
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
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en
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Cop py
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Prote AG.

FOX 2004
2 Camshaft mechanism - repair

Camshaft - check axial clearance page 40 .
Valve seat - grind page 40 .
Valve guides - check page 42 .
Valve stem seal - replace page 43 .
2.1 Camshaft mechanism - repair

AG. Volkswagen AG d
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Engine
s a head cylinder with fractures between valves seats
or be
ra
c
tween valve seat and Spark plug - Q- thread can still be used
s
ce
le
without reducing the useful life, provided that the fractures are 0.5
un
pt
an
d
mm wide at most or are located on the first 4 turns of the Spark

itte
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plug -Q- thread only.
ab
ility
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WARNING
spec
t to the co
torque
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mer
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om
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or
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Cop py
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2. Camshaft mechanism - repair 37

FOX 2004

be ground.
With integrated cam
shaft bearings.
old gasket. AG. Volkswagen AG d
agen oes
Before installation, ap Volksw not
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y
ply a coat of Sealing putsed b ara
nte
ty for engines -AMV 188 thori
eo
001 02- . ss au ra
c
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
engine cylinder head
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holes.
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hole
spec
2 - 6 Nm + 90
es, in part or in w
t to the co
moval.
Tighten from inside out.
rrectness of i
3 - Camshaft
l purpos
Check axial clearance

page 40 .
nform
ercia
Check radial clearance

with plastigage, wear
m
at
om
limit 0.1 mm.

ion
c
in t
r
Runout: max. 0.05 mm.

o
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ate
do
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4 - Roller rockers
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cum
or
Check roller rockers for

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en
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Lubricate sliding sur
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For installation, fit to the Prote AG.
support element with safety clip.
5 - Support element
Do not change positions.
With valve clearance hydraulic offsetting.
6 - Keys
7 - Valve spring plate
8 - Valve spring
With engine cylinder head removed, use the Compression device -2037- .
With engine head installed page 43 .
9 - Valve stem seal
Replace page 43 .
10 - Engine cylinder head
Sealing surface on camshaft side cannot be ground.
Grind valve seats page 40 .
Grind sealing surface on engine block side page 39
11 - Valves
Do not grind, may be seated only.
Valve specifications page 40

FOX 2004
12 - 20 Nm + 90
13 - Gear
From Camshaft
Immobilise the gear with the Special wrench -3036 - .
Grind sealing surface on the engine block side

Cylinder head grinding specification: -a- = at least 135.6 mm.
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FOX 2004
2.2 Camshaft - check axial clearance

Centesimal dial gauge
Support -VW 387-
Camshaft, check axial clearance

Measure with support elements and camshaft cover removed.
Press camshaft central bearing -arrow-, and check axial
clearance by moving the camshaft.
Wear limit: max. 0.20 mm.
Camshaft identification, distribution times AG. Volkswagen AG d
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Codes between intake and exhaust cams of cylinder 1 - BMD/ d by V o gu
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Cylinder 1 03DF ss a c
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Distribution times for 1-mm valve clearance
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BMD/CHFB engine
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Intake valve Exhaust valve
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Then opens TDC 11 48` --------
hole
spec
Then closes BDC 27 26` --------
es, in part or in w
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Opens be BDC --------- 36 28`
fore
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Closes be TDC --------- 1 46`
fore
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Valve specifications
nform
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Note
ion
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Valves cannot be ground. They may be seated only.

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Specification Intake valve Exhaust valve

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a mm 34,5 28,0
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b mm 5,98 5,96
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c mm 99,25 99,25
AG.
a ? 45 45
2.3 Valve seat - trim


FOX 2004
Depth vernier caliper

Device for grinding valve seats
Note
In case of repairs to engines with leaking valves, simply grind

ing or replacing the seats and valves is not enough. Especially
in engines with high kilometres traveled, the valve guides must
also be checked for wear. page 42 .
Grind valve seats until obtaining a perfect seating. Before
grinding, determine the maximum grinding elevation allowed.
If grinding elevation is exceeded, hydraulic offsetting of valve agen AG. Volkswagen AG do
clearance is no longer ensured and the engine cylinder yhead Vol
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must be replaced. ised b ua
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Calculating maximum trimming specification allowed
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pt
Install the valve and press it strongly against its seat.
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Note
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hole
If the valve is replaced upon repair, use the new valve for meas
spec
urement.
es, in part or in w
t to the co
Measure the distance -a- between valve end and engine head
upper surface.
rrectness of i
Calculate maximum and minimum grinding measurement of
l purpos
the measured distance.

Minimum measurements: Intake valve = 7.6 mm and exhaust
nform
ercia
valve = 7.6 mm.

m
at
Measured distance minus minimum distance = Maximum grinding
om
io
measurement allowed.
n
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Example:
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Measured distance 8,0 mm

f
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- minimum specification 7,6 mm

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Maximum allowable grinding specification 0,4 mm ht. rig
rig ht
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The max. grinding measurement allowed is shown in the illustra
by lksw
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tions to grind the valve seats as per measurement b.
AG.
Grind intake valve seats

a = 32,9 mm
b = max. trimming specification allowed
c = max. 1.8...2.0 mm
Z = Lower cylinder head edge
a = 45 Valve seat angle
= 30 Upper correction angle
? = 60 Lower correction angle
3) Calculating maximum grinding measurement allowed page 40 .

FOX 2004
Grind exhaust valve seats

a = 26.6 mm
b = max. trimming specification allowed
c = max. 1.8...2.0 mm
Z = Lower cylinder head edge
a = 45 Valve seat angle
= 30 Upper correction angle
? = 60 Lower correction angle
4) Calculating maximum grinding measurement allowed page 40 .
2.4 Valve guides - check

Centesimal dial gauge
Support -VW 387-
wage es n
Test sequence yV
olks ot g
ua
b
ed ran
Place a new valve on the guide. Valve end shall thor be aligned
is tee
or
with guide. Due to the various valve guide diameters,
au we rec ac
ss
ommend using only one intake valve on intake guide and one
ce
le
exhaust valve on escape guide.

un
pt
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Measure tilting clearence. Wear limit: 0.8 mm.

rm
ab
pe
ility
In case the clearance is exceeded:

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Replace engine cylinder head.

hole
spec
es, in part or in w
t to the co
rrectness of i
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mercia
a
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tion in
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by
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Prote AG.

FOX 2004
2.5 Valve stem seal - replace

equipment required
Support -VW 061- or Sup
port -10-222A-
Support -10 - 222 A /1-
Spark plug wrench -3122B-
Valve spring compressor
-3362- with Pressure part
-3362/1-
Seal fitter -3365-
AG. Volkswagen AG d
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cial p
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mer
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Prote AG.

FOX 2004
Wrench -3415-
Pins -3415/1-
Flexible tube -VW 653/2A-
or Flexible tube -VW 653/3-
AG. Volkswagen AG d
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un
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erm
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ot p
wit
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spec
t to the co
rrectness o
cial p
f inform
mer
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om
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te
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2.5.1 Removal
AG.
(with engine head installed)

Remove cylinder head cover page 24 .
Remove roller rockers and place them on a clean surface.
Make sure roller rockers are not touched.
Remove the spark plugs with the Spark plug wrench -3122B- .
Put the piston of the respective cylinder in Bottom Dead Cen
tre.

FOX 2004
Install Valve spring compressor -3362- with the -3362/1- .

Screw the Flexible tube -VW 653/2A- or Flexible tube -VW
653/3- to the spark plug thread.
Connect pressure tube to compressed air with, at least, 6-bar
positive pressure and remove valve springs.
Remove valve stem seals with the Impact extractor -3364- .
AG. Volkswagen AG d
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2.5.2 Installation
nl
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Install the supplied plastic bushing on the respective valve
erm
ab
ility
stem. This way, damages to the valve steam seal are preven
ot p
ted.
wit
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hole
Install the new valve steam sealant in the Seal fitter -3365- .
spec
es, in part or in w
Lubricate the valve stem seal lip and carefully install on valve
t to the co
guide.
Install cylinder head cover page 24 .
rrectness of i
l purpos
nform
mercia
at
om
ion
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or
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ate
do
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Prote AG.

FOX 2004
17 Lubrication system
1 Lubrication system components - re
move and install
Note
Oil level shall not exceed the max. mark! - risk of damages to the
catalytic converter! Marks page 48
WARNING

torque
Engine oil (filling capacities, engine oil specification)

page 46 .
Oil crankcase - remove and install page 48 .
Oil pressure and Oil pressure switch -F1- - check page 50 .
1.1 Engine oil

Oil supply capacities
With oil filter 2.85 l.
Engine oil specification
Use oils with high lubrication grade, according to the specifica
en AG. V
olkswagen AG
tions in Lubricant oil for engines -VW 502 00- . olkswag does
no
yV t gu
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spec
es, in part or in w
t to the co
rrectness of i
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at
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ion
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or
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ate
do
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Prote AG.
46 Rep. Gr.17 - Lubrication system

FOX 2004
1 - Oil pressure switch - F1-

0.3...0.6 bar, 25 Nm
2 - Guide bushing
3 - Oil pump
Replace only the com
plete set.
4 - 25 Nm
5 - Crankcase
Remove and install with
liquid joint page 48 .
Clean sealing surface
before installation.
Install with Silicone
sealant -D 176 404 A2 -
page 48 .
6 - 15 Nm
7 - Sealing ring
Replace.
8 - Oil draining plug, 30 Nm
With sealing ring. n AG. Volkswagen AG do
lkswage es n
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Replace. byV ua
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ir se tee
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9 - 8 Nm auth or
ac
ss
10 - Cover
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11 - 20 Nm + 90
itte
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moval.
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12 - Gear
ole,
spec
From roller chain
Item 13 (page 47) .
t to the co
After installation, adjust
distribution times page 32 .
rrectne
13 - Roller chain
Mark rotation direction before removal (installation positions).
ss o
cial p
f
14 - Chain stretcher with tensioning chute
inform

mer
atio
m
15 - 15 Nm
o
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16 - Chain gear
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17 - Supporting bushing
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Prote AG.
19 - 90 Nm + 90
Fit lubricated.
Immobilise crankshaft pulley with Spanner -3415- .
The additional angle torque can be measured with a spanner, e.g. Hazet 6690.
20 - Oil level and temperature sensor -G266-
Not applicable.
1. Lubrication system components - remove and install 47

FOX 2004
21 - Guide tube
22 - Oil dipstick
Oil level shall not exceed the max. mark! !
Marks page 48
23 - Support
24 - Oil Filter
Tighten manually.
25 - 25 Nm
Marks on the oil dipstick

1- max. - marks.
2- min. - marks.
3- -a- - Region between the upper corner of the engraved re
gion and the max. mark: do not replenish with oil.
4- -b- - Level is on the engraved area: the oil may be refilled.
5- -c- - Area between min. mark and lower corner of engraved
area: refill, at most, 0.5 l of oil
1.2 Oil crankcase - remove and install

AG. Volkswagen AG d
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es, in part or in w
Portable drilling machine with plastic brush

t to the co
Flat spatula
rrectness of i
Silicone sealant for engine -D 176 404 A2-

l purpos
Goggles
1.2.1 Removal
nform
ercia
Drain engine oil.

m
a
com
tio
Remove fastening nuts from exhaust front tube on catalytic

n in
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converter and from support strap on transmission.

thi
s
iva
do
Move front tube away.

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Remove crankcase fastening bolts.

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Remove oil crankcase. If necessary, loosen oil crankcase by ht. rig
rig ht
tapping slightly with a rubber hammer. py by
co Vo
by lksw
cted agen
Prote AG.

FOX 2004
Remove with a flat spatula the residues of Engine silicone

sealant -D 176 404 A2- present on the engine block.
Remove Engine silicone sealant -D 176 404 A2- residues from
oil crankcase with a portable drill and plastic brush (wear gog
gles).
Clean the sealing surfaces. Must be lubricating oil free.
1.2.2 Installation
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
by
Observe the expiry rdate
ised for the Engine silicone sealant -D 176
ara
nte
404 A2- . ut
ho eo
ra
s a c
Oil crankcase smust be installed within five minutes after ap
ce
e
plying the Engine silicone seal - D 176 404 A2- .

nl
pt
du
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itte
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The oil crankcase is more easily and safely installed if threa
erm
ab
ded bolts M6 are used as guides in two points of the engine
ility
ot p
block flange.
wit
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hole
spec
Cut the tube nozzle by the front mark ( nozzle approx. 3 mm).
es, in part or in w
t to the co
Apply the Engine silicone sealant -D 176 404 A2- , as shown,

onto clean sealing surface of oil pan. The cord of Engine sili
cone sealant -D 176 404 A2- must be:
rrectness of i
2...3 mm thick
l purpos
Circle from inside the bolt holes -arrows-.

nf
ercia
or
Note
m
m
atio
om
n in
c
The Engine silicone sealant - D 176 404 A2- cord should not be
or
thi
thicker, otherwise, the excess Engine silicone sealant -D 176 404

te
sd
iva
A2- may reach the oil pan and clog the filter in the oil suction tube.
o
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rp
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Immediately install the oil crankcase and tighten bolts in the
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indicated sequence: t. C rig
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Tighten oil crankcase bolts to 15 Nm torque.
o Vo
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Prote AG.
Note
After installing the crankcase, the Engine silicone sealant -D 176

404 A2- must dry within approximately 30 minutes. After that, the
engine may be replenished with engine oil.

FOX 2004
1.3 Oil pressure and Oil pressure switch -F1- - check

equipment required
Oil pressure gauge -VAG
1342 -
wage es n
Voltage control -VAG yV
o1527
lks ot g
ua
B- ise
d b ran
r tee
ho
Auxiliary measuring
sa
ut cable or
ac
set - VAG 1594 C-
s
ce
e
nl
pt
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itte
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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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t. rig
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Prote AG.
1.3.1 Check conditions

Oil level OK - check page 48
Engine oil temperature, at least 176 F (the Radiator fan -V7-
must have been activated at least once).
Note
Operation and repair test of oil pressure visual and acoustic indi
cators. Current flow diagrams, Electrical fault finding and Fitting
locations.

FOX 2004
1.3.2 Oil pressure and Oil pressure switch -

F1- - check
Note
Operation and repair test of oil pressure visual and acoustic indi
cator: Current flow diagrams, Electrical fault finding and Fitting
locations
Test sequence
AG. Volkswagen AG d
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Remove Oil pressure switch y-F1-
Vol and install it on the Oil pres
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sure gauge -VAG 1342- is. ed b ua
ran
r tee
ho
Install the Oil pressure
au meter -VAG 1342- in place of the Oil
t or
ac
pressure switch -F1- ss on the engine head.
ce
le
un
pt
Put tester brown cable on the earth (-).
an
d
itte
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rm
ab
Connect the Voltage control -V.A.G 1527 B- with Auxiliary ca
pe
ility
ble -V.A.G 1594 A- to the Battery -A- positive terminal (+) and
ot
wit
Oil pressure switch -F1- . The LED shall not light up.
, is n
h re
hole
If it the LED lights up, replace the Oil pressure switch -F1- .
spec
es, in part or in w
Run the engine and slowly increase the speed (rpm). With a
t to the co
0.3...0.6-bar positive pressure, the LED should light up, oth
erwise, replace the Oil pressure switch -F1- .
rrectness of i
Keep on increasing the speed. At 2000 rpm and an oil tem
perature of 80C, the positive oil pressure should be at least
l purpos
2.0 bar.
At higher speeds, positive oil pressure may not exceed 7.0 bar.
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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by c lksw
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Prote AG.

FOX 2004
19 Cooling system
1 Cooling system components - re n AG. Volkswagen AG do
move and install by
Volkswage es n
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ris
tho e or
WARNING au ac
ss
ce
e
During the works, especially within the engine compartment, nl
pt
du
an
itte
due to the shortage of space, take the following into account:
y li
erm
ab
All hoses (e.g. fuel, hydraulics, activated charcoal filter
ility
ot p
system, cooling system and cooling gas, brake fluid, vac
wit
, is n
h re
uum) and electric cables must be restored to their original
hole
positions.
spec
es, in part or in w
Provide easy access to all the moving or hot parts.
t to the co
rrectness of i
Note
l purpos
The cooling system is under pressure when the engine is hot.
nf
ercia
Thus, it is necessary to reduce the pressure before doing re
orm
pairs.
m
atio
om
n in
Hose connection are fastened by spring clamps. When doing
or c
repairs, use spring clamps only.
thi
te
sd
iva
o
To remove and install spring clamps, we recommend using the
r
rp
cu
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m
VAS 5024A or Standart-type clamp pliers -VW 5162- or Pliers
f
en
ng
t.
-V.A.G 1921- .
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Cop py
t. rig
The cooling system hoses should be installed without tension
gh ht
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and without coming into contact with other components (ob
cop Vo
by lksw
cted
serve the marks on the hose connections).
agen
Prote AG.
With hot engine, the cooling system is under pressure. Elimi

nate pressure before carrying out repairs.
Check for cooling system leaks using the Engine cooling system
tester -V.A.G 1274 - or Engine cooling system tester -VAG 1274B-
with the Adapter -V.A.G 1274/8 - and Adapter -V.A.G 1274/9- .
Cooling system components, body side page 53 .
Cooling system components, engine side page 54 .
Cooling system - drain and replenish page 56 .
Radiator - remove and install page 59 .
Water pump - remove and install page 60 .
Proportion for coolant mixture page 56 .
52 Rep. Gr.19 - Cooling system

lkswage es n FOX 2004
o ot g
byV 3 - Cyl. injection engine u-a Edition 12.2009
ed ra
ris nte
utho eo
ra
1.1 Cooling system components on body side ss
a c
ce
e
nl
pt
du
an
itte
y li
1 - Radiator
erm
ab
ility
Remove and install
ot p
wit
page 59 .
, is n
h re
After replacement, ex
hole
spec
change all coolant.
es, in part or in w
t to the co
2 - Sealing ring
Replace.
rrectness of i
3 - Upper cooling system hose
l purpos
Fixed to the radiator with

retaining clip.
Check for proper seat
nform
ercia
ing.
m
at
Cooling system hose
om
ion
connection diagram
c
in t
or
page 55 .
his
ate
do
riv
4 - Air deflector
p
cum
for
en
ng
5 - 10 Nm
t.
yi Co
Cop py
. rig
6 - Right radiator fan. -V35-
t
gh ht
pyri by
Vo
o
Vehicles with air condi
c by lksw
cted agen
tioning only. Prote AG.
7 - Retaining clip
ing.
8 - Support
For Radiator fan -V7- .
9 - Connectors
From cooling system
fans.
10 - Radiator fan -V7-
11 - For cooling system ther
mostat valve body
Cooling system hose connection diagram page 55 .
12 - Coolant reservoir
Check for cooling system leaks using the Engine cooling system tester -VAG 1274- or Engine cooling
system tester -VAG 1274B- and the Adapter for VAG 1274 -VAG 1274/8- .
13 - Lid
Check with the Engine cooling system tester -VAG 1274- or Engine cooling system tester -VAG 1274B-
and Adapter for VAG 1274 -VAG 1274/9- .
Test pressure 1.4 ... 1.6 bar.
14 - Support
From radiator fan coupling connector -V7- .
15 - Lower cooling system hose
Fixed to the radiator with retaining clip.
Check for proper seating.
Cooling system hose connection diagram page 55 .
16 - Thermal switch -F18- , 35 Nm
For Radiator fan -V7- .
1. Cooling system components - remove and install 53

FOX 2004
Switch temperatures:
Speed 1: on: 95 C; off: 84 C.
Speed 2: on: 102 C; off: 91 C.
17 - Support
For the radiator
Check installation position.
Observe different versions.
18 - 10 Nm
1.2 Cooling system components, engine

side
Thermostat valve body side
1 - 10 Nm
2 - Sealing ring
Replace.
3 - Clip
ing.
4 - To upper side of radiator.
Cooling system hose
connection diagram.
5 - From lower side of radiator.
Cooling system hose
connection diagram.
AG. Volkswagen AG d
agen oes
6 - Thermostat valve body olksw not
V gu
d by ara
Thermostat valve - Ini orise nte
tial opening tempera aut
h eo
ra
ture 87...102 - final ss c
130C.
ce
le
un
pt
an
d
Thermostat valve - Ini

itte
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tial opening 8 mm - final

rm
ab
pe
ility
12 mm.
ot
wit
, is n
7 - Clip
h re
hole
spec

es, in part or in w
ing.
t to the co
8 - For heat exchanger

Cooling system hose
rrectness of i
connection diagram.
l purpos
9 - From the heat exchanger

Cooling system hose
nform
ercia
connection diagram.
m
10 - Cooling system pipe

a
com
tion in
Cooling system hose

r
te o
thi
connection diagram.
s
iva
do
r
11 - Sealing ring
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cum
fo
en
g
Replace.
n
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

FOX 2004
12 - Engine block water pump housing

13 - 10 Nm
14 - Coolant temperature sensor -G62-
Before removing, eliminate, if necessary, cooling system pressure.
1.3 Cooling system hose connection diagram
1 - Coolant reservoir
2 - Heat exchanger
3 - Lower cooling system hose
4 - Radiator
5 - Upper cooling system hose
6 - Thermostat valve body
AG. Volkswagen AG d
7 - Engine cylinder head / en ksw
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8 - Water pump uthor eo
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9 - Cooling system pipe s
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10 - Intake manifold
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FOX 2004
1.4 Cooling system - drain and replenish

equipment required
Refractometer for T 10007
or coolant analysis -EQ
7093-
VAS 5024A or Standart-
type clamp pliers -VW
5162-
Cooling system supply unit
-VAS 6096 -
lkswage es n
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1.4.1 Drain
, is n
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hole
spec
es, in part or in w
WARNING
t to the co
Hot vapours may escape from the coolant reservoir when

opening it. Wear protective clothing and goggles to prevent in
rrectness of i
juries to the eyes and burns. Place a cloth on the cover and
open it carefully.
l purpos
nform
ercia
Remove lower noise insulation from engine compartment.

m
Remove coolant reservoir lid.

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FOX 2004
Open the drainage device on the radiator cooling system

-arrow-.
Note
Observe the waste disposal standards!
Checking
Note
Only G 12 may be used as coolant additive, as per TL VW

774 F standard Identification feature: lilac colour
Lilac G12, according to TL VW 774 F standard, may be mixed
with the previous red G 12 coolant additive!
AG. Volkswagen
G 12 and coolant additives with
lksw the TL VW 774 F indication
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prevent damages caused db
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au
th the cooling system must be contain eo
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coolant with additive
ss all year round. c
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un
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Especially in tropical countries, the coolant contributes to the
an
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safe engine operation, when heavily stressed, by elevating
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boiling temperature.
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Antifreeze protection must be ensured up to around -25C (in
wit
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arctic climate countries, up to -35C).
hole
spec
Coolant concentration may not be reduced, by adding water,
es, in part or in w
t to the co
not even in hot seasons or warm countries. Coolant additive
percentage must be at least 40%.
If, due to climate reasons, further antifreeze protection is re
rrectness of i
quired, G 12 percentage may be increased, but only up to 60%

(antifreeze protection of around -40C), otherwise, this pro
l purpos
tection is reduced again and hinders cooling efficiency.

If radiator, heat exchanger, engine cylinder head or engine
nform
ercia
cylinder head gasket have been replaced, do not apply the

m
used coolant again.

com
tion in
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Recommended mixture proportion:

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Antifreeze Antifreeze G 12 (l) G 12 Water (l) Water

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up to percent 5)
(gal)5) 5)
(gal)5)
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5) The coolant volume may vary according to the equipment on each vehicle.
Close the drainage device for the cooling system -arrow-.

Install engine compartment lower noise insulation.

FOX 2004
1.4.2 Refill
With Cooling system supply unit -VAS 6096-
Fill cooling system circuit with Cooling system supply unit -
VAS 6096- : Instructions for using cooling system supply
unit near VAS 6096.
Without the Cooling system supply unit -VAS 6096-
Fill with coolant up to the max. mark on the coolant reservoir.
With or without Cooling system supply unit -VAS 6096-
Close the coolant reservoir.
Turn off heating command.
Operate the engine and keep engine speed for 3 minutes at
approx. 2000 rpm.
Let the engine running until starting the Radiator fan -V7- op
eration.
WARNING
Hot vapours may escape from the coolant reservoir when

opening it. Wear protection goggles and clothing to prevent in wagen AG. Volkswagen AG doe
juries to the eyes and burns. Place a cloth on the coveryand Vol
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open it carefully. ise
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Check coolant level, and if necessary, add more coolant.
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When the engine is hot, the level of coolant in the reservoir
du
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must be in the max. mark; when it is cool, in the medium level,
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between min. and max. marks.
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FOX 2004
1.5 Radiator - remove and install

equipment required
Refractometer for T 10007
or coolant analysis -EQ
7093-
VAS 5024A or Standart-
type clamp pliers -VW
5162-
(enc. 1/2") -VAG 1331-
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1.5.1 Removal
rm
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Put front panel in the work position: Body - external assem

or c
bly works; Rep. Gr. 50 ; Body - front part

thi
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Drain the cooling system page 56 .

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Loosen cooling system hoses from radiator

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Cop py
Disengage the connectors from the Radiator fan thermal ht. rig
rig ht
by
switch -F18- and from the Radiator fan -V7- . copy Vo
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Remove radiator securing scrrews and remove radiator with
AG.
Radiator fan -V7- from below.

Observe additional indications and installation works

FOX 2004
Note
To prevent damages to the condenser, as well as to the cooling

gas pipes, it is necessary to ensure the hoses are not stressed,
bent or deformed.
Loosen cooling gas pipes brace(s).

Volkswagen AG
Loosen radiator condenser and fasten it to the front panel.swagen AG. does
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1.5.2 Installation oris
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Install in reversed order, considering the following:au ra
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Fill cooling system page 56 . un
pt
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Electrical connections and installation: Current flow dia
erm
ab
grams, Electrical fault finding and Fitting locations.
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1.6 Water pump - remove and install
h re
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spec
t to the co
rrectness o
cial p
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mer
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FOX 2004

Refractometer for T 10007 or coolant analysis -EQ 7093-
VAS 5024A or Standart-type clamp pliers -VW 5162-
Water pump wrench -VAG 1590-
Due to changes in water pump pulley fastening bolts, file the
three round shoulders at least: -a = 1 mm-.
Note
Water pump integrated gasket may not be separated from the

pump.
In case of damages and leaks, replace the entire pump to
gether with the gasket.
1.6.1 Remove lksw

agen
AG. Volkswagen AG d
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Drain the cooling system pageis56 ed .
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Remove the Poly-V belt pageaut 13 . ra
ss c
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Remove water pump pulley.
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nl
pt
du
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Remove water pump fastening bolts.
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Remove water pump
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1.6.2 Installation
h re
hole
spec
Install in reversed order, considering the following:
es, in part or in w
t to the co
Install the crankcase water pump.
Tighten the fastening screws with 25 Nm.
rrectness of i
Tighten water pump pulley fastening bolts to 20 Nm.
l purpos
Install Poly-V belt page 13 .

nform
ercia

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FOX 2004
20 Supply system - tank, Fuel pump (pre-supply pump) -

G6-
1 Fuel supply system components - re
move and install
Note
Always replace fastening clamps with spring clamps.

Fuel tubes in the engine may be fastened with spring clamps
G. Volkswage
only. Using tightening clamps andlkbolted
swa clamps is not
gen A al oes n
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To install spring clamps,uthwe
or recommend using VAS 5024A or tee
or
Standart-type clamp pliers
ss
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nl
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du
Fuel supply system components - remove and install
an
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page 63 .
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Safety measures for working on the fuel supply system
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page 65 .
h re
hole
Follow cleaning rules page 65 .
spec
es, in part or in w
t to the co
Fuel pump (pre-supply pump) -G6- - remove and install
page 66 .
Fuel level indicator sensor -G- - remove and install page 67 .
Fuel tank - remove and install page 68 . rrectness of i
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Fuel shut off in case of accident page 70 .

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Fuel pump (pre-supply pump) -G6- - check page 71 .

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Supply system - drain the air page 78 .

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62 Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6

FOX 2004
1.1 Fuel supply system components - remove and install
1 - Fastening clip
2 - Reservoir lid
3 - Sealing ring
Replace if damaged.
4 - Fastening screw
5 - Fuel supply nozzle com
partment cover
With rubber bellows.
Remove and install
Body - External assem
bly works; Rep. Gr. 55 ;
Hoods .
6 - Vent valve
7 - Gravity valve
Remove rear right
wheel case protector.
Remove the cover from
fuel tank nozzle com
partment with bellows.
Check valve passage
continuity. Perpendicu AG. Volkswagen AG d
lar valve: open. Valve in lksw
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8 - Fuel supply tube ut
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9 - Spring clamp s
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un
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10 - Fuel reservoir
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Remove using the En

ab
pe
ility
gine / gearbox or VAG

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1383A jack. -EQ 7081- .

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Remove and install

hole
spec
page 68 .
es, in part or in w
t to the co
11 - 23...29 Nm
12 - Pipes
rrectness of i
Anti-choke for fuel tank up to expansion tank.

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13 - Pipes
Venting for fuel tank up to expansion tank.
nform
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14 - Bearing
m
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15 - Expansion reservoir
on in
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16 - Pipes
s
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Anti-choke for the fuel tank supply nozzle housing.

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17 - Pipes
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Venting for the fuel tank supply nozzle housing. t. C rig
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18 - Fuel pump (pre-supply pump) -G6-
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Remove and install page 66 .
AG.
Clean the filter, in case it is dirty.

Fuel pump (pre-supply pump) -G6- - check page 71 .
Observe the flange installation position in the fuel tank page 64
1. Fuel supply system components - remove and install 63

FOX 2004
19 - Sealing gasket Fuel pump (pre-supply pump) -G6-

20 - Circlip (sliding)
21 - Supply pipes
Black.
Make sure it is well fastened.
For fuel distributor.
22 - Return pipes
Blue.
Fastened laterally to the fuel tank.
Make sure it is well fastened.
1 - For the fuel tank supply noz

zle housing.
2 - For activated charcoal filter
3 - For the fuel tank supply noz
zle housing.
4 - Expansion reservoir
5 - For expansion tank
6 - For expansion tank
AG. Volkswagen AG d
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Installation position for Fuel pump (pre-supply pump) -G6-

ole,
spec
The -arrow- on the Fuel pump (pre-supply pump) -G6- shall match
t to the co
to that on the reservoir.

rrectne
Note
s
After installing the Fuel pump (pre-supply pump) -G6- , check if

s o
supply, return and vent pipes are still fastened to the fuel tank.
cial p
f inform
mer
atio
om
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c
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64
agen
Prote AG.
Rep. Gr.20 - Supply system - tank, Fuel pump (pre-supply pump) G6
FOX 2004
Check vent valve

Lever in rest position: closed
Lever pushed in the direction of arrow: open
Note
Before vent valve installation, remove fuel tank cover.
1.2 Safety measures in fuel supply works
WARNING
Fuel supply tube is under pressure! Wear protective goggles

and gloves to prevent injuries and avoid contact with the skin.
Before loosening tube junctions, place a cloth around the union
point. Then, eliminate pressure by pulling the tube carefully.
Caution
In all assembly works, especially in engine compartment, due

to lack of space, consider the following:
agen
AG. Volkswagen AG d
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All pipes (e.g. fuel,d bhydraulic,
yV activated charcoal filter,
t gu
ara
cooling systemoand ris cooling gas, break fluid, vacuum) andntee
e
electric cables
au must be restored to original interconnec
th or
ac
tion. ss
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nl
pt
Ensure enough space in relation to all moving or hot com

du
an
itte
ponents to avoid damages to the connections.

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When removing and installing Fuel pump (pre-supply pump) -G6-

h re
hole
with fuel tank full or partially full, consider the following:

spec
es, in part or in w
Before starting installation works, place near the fuel reservoir

t to the co
opening, a suction hose for extracting equipment in operation,

to absorb gases released by the fuel. If extracting equipment
is unavailable, use a radial fan (the engine must be out of air
rrectness of i
flow) with air movement rate higher than 15 m3/ hour.

l purpos
Avoid skin contact with the fuel! Wear fuel resistant gloves!
For safety reasons, before opening the fuel system, remove
nform
ercia
fuse number 33 from fuse holder, as the Fuel pump (pre-sup

m
ply pump) -G6- can be activated.

at
om
ion
c
1.3 Cleaning rules

in t
or
his
ate
do
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To carry out fuel supply/injection works, consider the following 5

p
cum
or
cleaning rules thoroughly:

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Carefully clean union points and respective surrounding areas Cop py
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before disconnecting them. opyri
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Place parts on clean surface and cover them. Do not use cloth Prote
cted agen
that releases lint!
AG.
Carefully cover or close open parts, in case repair is not carried

out immediately.

FOX 2004
Install clean parts only: Remove parts from the packaging im

mediately before installation. Do not use parts that have been
kept out of the packaging (for example, in tool boxes).
With system open: Do not work wit compressed air. Do not
move the vehicle.
1.4 Fuel pump (pre-supply pump) -G6- - re

move and install
Spanner -VW 5321/9- or Spanner -T10334-
AG. Volkswagen AG d
agen oes
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1.4.1 Removal
hole
spec
es, in part or in w
Take safety precautions before starting removal works

t to the co
page 65 .
rrectness of i
First, check if the vehicle has code radio; if so, check the re
l purpos
spective anti-theft code.

With ignition off, disconnect earth strap from Battery -A- .
nform
ercia
Fold rear seat forwards.

m
at
om
Remove Fuel pump (pre-supply pump) -G6- access cover.

on
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or
his
ate
WARNING
do
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for
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Fuel supply hose is under pressure. Before loosening hose

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junctions, place a cloth around them. Next, eliminate pressure C py
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by removing hose carefully.
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Remove return -1- and supply -2- pipes and connector -3- from
Fuel pump (pre-supply pump) -G6- .

FOX 2004
The -arrows- shows the installation position of the Fuel pump (pre-
supply pump) flange -G6- .
Note
To remove fuel hoses, press the safety key located under the
connection.
Remove the lock with Wrench -VW 5321/9- or Wrench -

T10334- .
Remove the Fuel pump (pre-supply pump) -G6- and the seal
from the opening in the fuel tank.
Note
In case of replacing the Fuel pump (pre-supply pump) -G6- , emp

ty the old Fuel pump (pre-supply pump) -G6- before disposing it.
1.4.2 Installation
Fuel pump (pre-supply pump) -G6- must be installed in the
reverse sequence to the removal.
AG. Volkswagen AG d
agen oes
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Try not
ss a to bend the Fuel level indicator sensor -G- during c in
stallation.
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Install Fuel pump (pre-supply pump) -G6- sealing dry on fuel

itte
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tank opening.
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Lubricate the sealing with fuel only for installing the Fuel pump
wit
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(pre-supply pump) -G6- .

h re
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spec
Observe installation position of the Fuel pump (pre-supply

es, in part or in w
pump) -G6- -arrow-.

t to the co
The mark on the Fuel pump (pre-supply pump) -G6- shall

match that on the body.
rrectness of i
Check the firm seating of the fuel hoses.

l purpos
Do not confuse the supply and return hoses.

nf
ercia
After installation of the Fuel pump (pre-supply pump) -G6- ,

or
check whether the supply, return and vent pipes are still fas
m
m
atio
tened to the fuel reservoir.

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or c
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sd
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1.5 Fuel level sensor -G- - remove and in

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op Vo
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Remove Fuel pump (pre-supply pump) -G6- page 66 .

FOX 2004 AG. Volkswagen AG d
agen oes
3 - Cyl. injection engine - Edition 12.2009 Volksw not
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Disengage the connector from the Fuel level indicator sensor
utho eo
ra
-G- by displacing the lock-1-and moving the connectorssin
a c
-arrow a-direction.
ce
le
un
pt
an
d
Press lock -2- and move the Fuel level indicator sensor -G- -3-
itte
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upwards-arrow b-.
erm
ab
ility
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h re
ole,
spec
t to the co
rrectness o
cial p
f inform
1.5.2 Installation
mer
atio
om
n
Position the Fuel level indicator sensor -G- on the Fuel pump
c
i
or
n
(pre-supply pump) guides -G6- and press it downwards until it
thi
te
sd
a
fits.
iv
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pr
cum
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Install the Fuel level indicator sensor -G- connector.
en
ng
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1.6 Fuel reservoir - remove and install
C py
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FOX 2004
Transmission jack or engine + transmission set -EQ 7081- or

Transmission jack or engine + transmission set -VAG 1383A-
1.6.1 Removal
Observe safety precautions before starting removal jobs
page 65 . AG. Volkswagen AG d
agen oes
lksw not
First, check if the vehicle has code radio; if so, check the d by re
Vo gu
ara
spective anti-theft code. orise nte
eo
h
ut ra
Remove the fuel reservoir lid. ss a c
ce
e
nl
With the ignition switched off, disconnect the Battery -A- earth
pt
du
an
strap.
itte
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erm
ab
Drain the fuel tank with Fuel absorption equipment - VAS
ility
ot p
5190- and clean around the fuel nozzle.
wit
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h re
hole
spec
es, in part or in w
Remove Fuel pump (pre-supply pump) -G6- access cover.
t to the co
Disengage the 4-pole connector from Fuel pump (pre-supply
pump) -G6-
rrectness of i
Remove fuel reservoir hoses next to the Fuel pump (pre-sup
l purpos
ply pump) -G6- .

Loosen exhaust system. The exhaust system must be fas
nform
ercia
tened to the body with wire, slightly lowered.

m
Remove heat deflector between the exhaust tube and the fuel
at
om
io
tank.
n
c
in t
or
his
e
Loosen fuel filter -1- supply hose.

at
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priv
c
Remove clamp from fuel supply tube near the tank with Stand
um
for
art-type clamp pliers -VW 5162- or Standart-type clamp pliers

en
ng
t.
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-VAS 5024A- . . Cop py
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Remove fastening bolts, supporting the fuel tank with the En py by
co Vo
gine / gearbox jack -EQ 7081- or Engine / gearbox jack - VAG
by lksw
cted agen
Prote
1383A- .
AG.
Lower fuel reservoir.
WARNING
Fuel supply hose is under pressure. Before loosening hose

junctions, place a cloth around them. Next, eliminate pressure
by removing hose carefully.
1.6.2 Installation
Installation is carried out by reversing the removal sequence,
considering the following:
Install vent and fuel hoses without bending them.

FOX 2004
Check the firm seating of the fuel hoses.

Do not invert supply and return hoses (return hose blue or with
blue marking, supply hose black).
Note
Once the fuel reservoir is installed, check if supply, return and

ventilation hose sets are still fixed.
If fuel tank has been replaced, it is necessary to drain the air
from the fuel system page 68 .
1.7 Fuel shut off in case of accident
1.7.1 Operation
The fuel is shut off in case of an accident in order to reduce risk
of fire in the vehicle after a collision, in which the Fuel pump (pre-
supply pump) -G6- is disconnected by the Fuel pump relay -J17- .
At the same time, with this equipment, the engine starts more
smoothly.
When opening the fuel system, consider the following safety pre
cautions page 65 . G. Volkswage nA n AG d
wage oes
Check the Fuel pump relay -J17- : CurrentyV
olks flow diagrams, not
gu
Electrical fault finding and Fitting locations
isedb ara
nte
r
ho eo
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
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.

. Volkswagen AG FOX 2004
gen AG does
swa
3 -y VCyl. injection engine - Edition
olk no12.2009
t gu
d b ara
ise nte
or
1.8 Fuel pump (pre-supply pump) -G6- - check h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
equipment required
erm
ab
ility
ot p
Spanner -VW 5321/9- or
wit
is n
Spanner -T10334-
h re
ole,
spec
Pressure gauge -VAG
1318-
t to the co
Adapter -VAG 1318/13-
rrectne
ss o
Torque wrench - 40 to 200 cial p
f i
Nm (enc. 1/2") -VAG 1332-
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

FOX 2004

equipment required
Adapting cable -VAG
1348/3-2-
Test probe -EQ 7300- or
Test probe -VAG 1527B-
Auxiliary measuring set -
VAG 1594A -
Multimeter -VAG 1715-
-Recipiente graduado-
Current flow diagrams,
Electrical fault finding and
Fitting locations
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
Fuse number 33 ok.

l purpos
Battery -A- voltage must be at least 11.5 V.

nform
ercia
All power consuming components, like lights and rear window

demister, must be off.
m
at
om
io
If the vehicle is equipped with air conditioning, turn it off.

n
c
in t
or
his
ate
do
priv
Note
um
for
en
ng
t.
yi Co
Observe the description of how fuel is shut off in case of accident Cop py
t. rig
page 70 . gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

FOX 2004
AG. Volkswagen AG d
3 - Cyl.
lks injection
wagen engine - Edition
oes 12.2009
n
o ot g
yV ua
edb ran
1.8.2 Operation of power supply - check tho
ris tee
or
au ac
ss
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
In the following operation sequence, it might be necessary to dis
ility
ot p
connect the Battery -A- earth strap. Therefore, check whether a
wit
, is n
code radio is fitted. If this is case, obtain the anti-theft code first.
h re
hole
spec
es, in part or in w
t to the co
Remove the cover beneath the seat.
Turn the ignition on. The Fuel pump (pre-supply pump) -G6-
rrectness of i
has to work audibly for approx. 1 second.
If the Fuel pump (pre-supply pump) -G6- does not work: l purpos
Turn the ignition off.
nf
ercia
orm
Remove fuse holder cover.
m
atio
om
n in
Remove fuse 33 from the ( Fuel pump (pre-supply pump) -
or c
G6- ) fuse holder.
thi
te
sd
iva
o
r
Connect the Remote control -VAG 1348/3A- and Adapter ca

rp
cu
o
m
ble -VAG 1348/3-2- to the lower contact of fuse 33 for activat
f
en
ng
t.
yi
ing the Fuel pump (pre-supply pump) -G6- and to the positive
Co
op py
terminal of Battery -A- (+). t. C rig
gh ht
pyri by
Activate the Remote control -VAG 1348/3A- .
o Vo
by c lksw
cted agen
Prote AG.
If the Fuel pump (pre-supply pump) -G6- works:
Check operation of Fuel pump relay -J17- , according to Cur
rent flow diagrams, Electrical fault finding and Fitting locations.
If the Fuel pump (pre-supply pump) -G6- does not work:
Disengage the 4-pole connector for the Fuel pump (pre-supply
pump) -G6-
Connect the Test probe -EQ 7300- or Test probe -VAG 1527B-
with Auxiliary cables -VAG 1594A- with Auxiliary cables to the
connector external contacts.
Activate the Remote control -VAG 1348/3A- .
The LED should light up.
If LED does not light up:
Locate and eliminate cable interruption, according to Current
flow diagrams, Electrical fault finding and Fitting locations.
The LED lights up (correct power supply):
Remove the Fuel pump (pre-supply pump) -G6- with the Span
ner -VW 5321/9- or Spanner -T10334- .
Check that the cables are connected to the Fuel pump -G23- .
In case there is no cable interruption:
Fuel pump (pre-supply pump) -G6- - damaged, replace.

FOX 2004
1.8.3 Fuel flow - check

1.8.4 Test conditions
Fuel pump (pre-supply pump) -G6- supply is ok.
Remote control -VAG 1348/3A- installed.
Fuel pump (pre-supply pump) -G6- pressure and fuel pressure
adjuster OK: page 98
1.8.5 Test sequence
Note
Fuel flow is measured at 3.0 bar for vehicles manufactured until

May/2006, and 4.0 bar for vehicles
wage
produced
n AG. V as
olkswagen AG dof
oesJune/2006.
Thereby, fuel pressurey Vmust
olks be checked before measuring not
gu the
flow. isedb ara
nt r ee
ho
aut or
ac
Remove sthe
s fuel reservoir lid.
ce
e
nl
pt
du
an
itte
WARNING
y li
erm
ab
ility
ot p
Fuel supply pipes are under pressure. Before loosening hose wit
, is n
connection, place a cloth around them. Next, eliminate pres

h re
sure by removing hose carefully.

hole
spec
es, in part or in w
t to the co
Disconnect fuel hose coupling-1- and clean the spilled fuel

with a cloth.
rrectness of i
Couple the Pressure gauge -VAG 1318 - to the fuel supply

tube, by using the adapters Connector -VAG 1318/23- and
l purpos
Adapter -VAG 1318/17- .

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
Connect the Pressure gauge -VAG 1318- hose to the Adapter
C py
t. rig
gh
-VAG 1318/11- and Adapter -VAG 1318/1- on the checking
ht
pyri by
Vo
o
Pressure gauge -VAG 1318- and place its end inside a grad by c lksw
cted agen
uated container with at least 3.0-liter capacity. Prote AG.
Open the Pressure gauge -VAG 1318- valve. It will indicate

the flow direction-A-.
Activate the Remote control -VAG 1348A- , closing the cock
slowly, until the Pressure gauge -VAG 1318- indicates a pos
itive pressure of 3.0 bar for vehicles manufactured until May/
2006, and 4.0 bar for those produced as of June/2006. Then,
do not change cock position.
Empty measuring container.
The Fuel pump (pre-supply pump) -G6- flow depends on the
Battery voltage -A- . Because of that, couple the Multimeter -
VAG 1715- to the vehicle Battery -A- , by using the Auxiliary
cables -VAG 1594A- .
Activate the Remote control -VAG 1348A- for 30 seconds,
measuring the Battery -A- voltage.

FOX 2004
Compare fuel flow with theoretical value for vehicles manu

factured until May/2006 ( Fuel pump (pre-supply pump) -G6-
pressure of 3 bar).
wage e
Compare fuel flow with theoretical
Vol
ks value for vehicles manu
s no
t gu
factured as of June/2006 d by ( Fuel pump (pre-supply pump) -G6- ara
ise nte
pressure of 4 bar).thor eo
au ra
c
ss 3/30 s
6) Minimum amount cm
ce
e
nl
pt
du
7) Voltage in the Fuel pump (pre-supply pump) -G6- with engine stopped and
an
itte
y li
Fuel pump (pre-supply pump) -G6- operating (approx. 2 volts less than Battery -
erm
ab
A- voltage).
ility
ot p
Example of reading:
wit
, is n
h re
During the test, a voltage of 12.5 volts is measured on the Battery
hole
spec
-A- . As in the Fuel pump (pre-supply pump) -G6- there is a voltage
es, in part or in w
of around 2 volts less than in the Battery -A- , the result is a min
t to the co
imum supply flow of 633 cm3>/30 s for vehicles manufactured
until May/2006 and 333 cm3/30 s for vehicles produced as of
rrectness of i
June/2006.
If minimum flow capacity is not reached:
l purpos
Check if the supply pipes to the filter present folds or obstruc

nform
tions.
mercia
If fuel pipes are ok.

at
om
ion
c
Check fuel flow before fuel filter.

in t
or
his
ate
do
priv
WARNING
um
for
en
ng
t.
yi Co
Fuel supply pipes are under pressure! Before loosening hose Cop py
t. rig
connections, put a cleaning cloth on connection points. Then yri
gh by
ht
depressurize by carefully pulling the hose. cop Vo
by lksw
cted agen
Prote AG.
Note
For that, press the keys on hose connectors.

FOX 2004
lkswage
3 - Cyl. injection engine - Edition 12.2009 es n
o V o t gu
by ara
ed nte
Remove supply hose-1- from fuel tho
rfilter inlet
is
and connect it to eo
Adapting set -VAG 1318/17- .s au ra
c
s
ce
e
Pressure gauge -VAG 1318- with Adapting set -VAG 1318/17-
nl
pt
du
as shown.
an
itte
y li
erm
ab
Install the adapter -V.A.G 1318/16- on the adapter -
ility
V.A.G 1318/11- for the Pressure gauge -VAG 1318- and put ot p
wit
, is n
its end in a graduated container with at least 3.0-liter capacity.
h re
hole
spec
Open the Pressure gauge -VAG 1318- valve. The cock points
es, in part or in w
towards the fuel passage-A-.
t to the co
Activate the Remote control -VAG 1348/3A- , closing the cock
slowly, until the Pressure gauge -VAG 1318- indicates a pres
rrectness of i
sure of 3.0 bar for vehicles manufactured until May/2006, and
4.0 bar for those produced as of June/2006. Do not change
l purpos
cock position.
Empty measuring container.
nform
ercia
Check flow again.

m
at
om
io
Activate the Remote control -VAG 1348/3A - once more for 30
n
c
in t
r
seconds. Compare the flow value with the one obtained in the
o
his
e
first measurement.
at
do
priv
cum
If the minimum flow is reached:
for
en
ng
t.
yi Co
Replace the fuel filter. t. Cop py
rig
gh ht
If the minimum flow is not reached again: yri
p by
co Vo
by lksw
cted
Remove the Fuel pump (pre-supply pump) -G6- and check
agen
Prote AG.
whether there is dirt in the screen filter.
Only if no irregularities have been found so far:
Fuel pump (pre-supply pump) -G6- - damaged, replace it
page 66 .
If the desired fuel flow is reached, but at great cost, we may con
clude that the fuel supply presents irregularities (i.e.: a momentary
fault in the fuel supply):
Couple the removed fuel tubes again.
By using the current leakage clamp meter, couple the Multi

meter -VAG 1715- to contact 1 (blue/white) 4-pole connection
socket box cable -arrow- from cable harness.
Start engine and let it run in idle speed.
Measure current draw of the Fuel pump (pre-supply pump) -
G6- .
Theoretical value: 6.8 ampere at most for vehicles manufactured
until May/2006 and 7.6 ampere for the ones produced as of June/
2006.
Note
If it is a temporary fault in the fuel system, checking can also take

place during a test drive, when the presence of a second person
will be necessary.
If the current draw is excessive:

Fuel pump (pre-supply pump) -G6- - damaged, replace it.

FOX 2004
1.8.6 Fuel pump (pre-supply pump) -G6-

check valve - check
Remote control -VAG 1348/3A- and Adapting cable -VAG
1348/3-2- connected.
1.8.8 Test sequence

AG. Volkswagen AG d
agen oes
ksw
WARNING
by
Vol not
gu
d ara
ise nte
or
Fuel asupply pipes are under pressure! Before loosening r a hose
h eo
ut
connections,
ss put a cleaning cloth on connection points.c Then
depressurize by carefully pulling the hose.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
This test must check simultaneously the tightness of joints on the
es, in part or in w
fuel supply tube sets, from the Fuel pump (pre-supply pump) -G6-
t to the co
to the joint on the Pressure gauge -VAG 1318- .
rrectness of i
Remove supply hose -1- from fuel filter inlet and connect it to
the Adapting set -VAG 1318/17- and the Pressure gauge -
l purpos
VAG 1318- .
Install the Adapter -VAG 1318/16- on the Pressure gauge -
nform
ercia
VAG 1318/11- Adapter and insert the hose -VAG 1318- end
in a measuring container.
m
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
Close the valve on the Pressure gauge -VAG 1318- (trans
yri
gh by
ht
verse valve in relation to the flow direction - position -B-).
op Vo
by c lksw
cted agen
Prote
Activate the Remote control -VAG 1348/3A- in quick consec
AG.
utive intervals, until reaching a pressure of approx. 3.0 bar for

vehicles manufactured until May/2006 and 4.0 bar for the ones
produced as of June/2006.
WARNING
Risk of splashing when opening the cock; keep a container in

front of the free end of the Pressure gauge -VAG 1318- .
Eliminate eventual excess pressure by opening the valve

carefully.
Check pressure drop on the Pressure gauge -VAG 1318- . Af
ter 10 minutes, the pressure must not drop below 2.0 bar.
If the pressure keeps dropping:
Check the joints for tightness.
If no irregularities are found in the pipes:
Fuel pump (pre-supply pump) -G6- - damaged, replace it.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
FOX 2004 ed b ara
nte
ris
3 - Cyl. injection engine - Edition 12.2009 ut
ho eo
ra
s a c
s
1.9 Supply system - drain the air
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
equipment required
wit
is n
h re
ole,
Remote control -VAG
spec
1348/3A- and Adapting ca
ble -VAG 1348/3-2- con
t to the co
nected.
Gasoil aspirator -VAS
rrectne
5226-
Adapter -V.A.G 1318/20-
ss o
cial p
f
Adapter -V.A.G 1318/20-1-
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.9.1 Conditions
The fuse must be ok.
Battery -A- voltage must be at least 11.5 V.
The Fuel pump relay -J17 - must be ok.
1.9.2 Operation sequence

Remove fuse holder cover.
G6- ) fuse holder.

FOX 2004
AG. Volkswagen AG d
lksw
agen oes
not 3 - Cyl. injection engine - Edition 12.2009
Vo gu
d by ara
e
Connecthothe
ris Remote control -VAG 1348/3A- and Adapter nte
eo ca
ble -VAG
au 1348/3-2- to the lower contact of fuse 33 for activat
t ra
c
ing the
ss Fuel pump (pre-supply pump) -G6- and to the positive
ce
le
terminal of Battery -A- (+).

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Remove the protection cover -arrow- from the drainage valve.
ss 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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Install the Adapter -VAG 1318/20-1- on the Adapter -VAG
Prote AG.
1318/20- .
Turn the valve (on T-part) counterclockwise until opening it
completely.
Install the Adapter -VAG 1318/20- manually on the drainage

valve.
Connect the Diesel aspirator -VAS 5226- tube, as illustrated.
Turn the valve (on T-part) clockwise up to the drainage valve
stop.
Check the tube adapters and connections for leaks.
Activate the Remove control -VAG 1348/3A- until bubble-free
fuel comes out of the drainage valve.
Turn the valve (on T-part) counterclockwise until opening it
completely.
Strangle the Diesel aspirator - VAS 5226- hose (e.g. with up
to 25-mm tubing clamps -3094- ) and remove it from the
Adapter -VAG 1318/20-1- .
Remove the Adapter -VAG 1318/20- from the drainage valve.

FOX 2004
AG. Volkswagen AG d
agen oes
olksw not
V gu
2 Activated charcoal filter system by ara
d
rise nte
tho eo
u ra
Operation page 80 . ss a c
ce
le
Activated charcoal filter system components - repair un
pt
an
d
page 81 .
itte
y li
rm
ab
Check fuel compartment ventilation page 81 .
pe
ility
ot
wit
, is n
2.1 Operation
h re
hole
spec
Fuel vapours form over the fuel surface on the tank, depending
es, in part or in w
on the atmospheric pressure and ambient temperature.
t to the co
The activated charcoal filter prevents these hydrocarbon emis
sions from being released into the atmosphere.
rrectness of i
The fuel vapours coming from the highest point of the tank go
l purpos
through the gravity valve (which closes at a 45 inclination) and

check valve, strangled in its amount, to the activated charcoal
filter.
nform
ercia
The activated charcoal absorbs these vapours like a sponge.

m
a
com
tion in
While driving and with Lambda adjustment active (hot engine),
r
te o
thi
the electromagnetic valve 1 for activated charcoal filter system -
s
iva
N80- , (also known as regeneration valve) is activated cyclically
do
r
rp
c
by the Engine control unit -J623- , due to engine speed and load.
um
fo
en
g
The opening period depends on the input signals.

n
t.
yi Co
op py
Intake manifold vacuum aspirates fresh air through the vent open
t. C rig
gh ht
yri
ing on the lower part of the activated charcoal filter, during the p by
co Vo
activated charcoal regeneration process. The fuel vapours stored
by lksw
cted agen
Prote
in the activated charcoal and the fresh air are fed for combustion
AG.
in dosed quantities.
The pressure retention valve prevents the fuel vapours from being
aspirated into the fuel reservoir, when the Magnetic valve I for
activated charcoal filter -N80- is opened and there is vacuum in
the intake manifold. This way, the activated charcoal filter regen
eration is ensured.
With no current (e.g., driver interruption) the Magnetic valve 1 for
activated charcoal filter -N80- remains closed. The activated char
coal filter will not be purged.
Note
The flexible tube joints are fixed with a quick coupling.

Always replace fastening clamps with spring clamps.
To install spring clamps, we recommend using the Standart-
type clamp pliers -VW 5162 - or Standart-type clamp pliers -
VAS 5024A- .
Follow safety measures page 65 .


FOX 2004
2.2 Activated charcoal filter system components - repair
1 - Activated charcoal filter re

generation system hose
2 - Pressure retention valve
with connection hose
Make sure it is well fas
tened.
From gravity valve.
3 - Activated charcoal filter
Installation location: in
the right rear wheel AG. Volkswagen AG d
case. agen oes
olksw not
V gu
by ara
4 - Vent connection rised
nte
ho eo
Ventilation visible from s aut ra
c
below. s
ce
e
nl
pt
du
5 - 10 Nm
an
itte
y li
erm
ab
6 - Accelerator butterfly valve
ility
ot p
control unit -J338-
wit
, is n
h re
7 - Magnetic valve 1 for activa
hole
ted charcoal filter tank -N80-
spec
es, in part or in w
The Magnetic valve 1 for
t to the co
the activated charcoal
reservoir -N80- will
close when the ignition
rrectness of i
is off.
l purpos
The Magnetic valve 1 for

the activated charcoal
reservoir -N80- is acti
nf
ercia
o
vated (by pulses) via
rm
m
Engine control unit - atio

m
J623- , when the engine

o
n in
c
is at the operating tem

or
thi
e
perature.
t
sd
iva
o
r
rp
cu
8 - Connector
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
2.3 Reservoir ventilation - check
p by
o Vo
by c lksw
cted agen
Prote AG.
Vacuum pump -VAG 1390- or Vacuum pump -VAS 6213-

The ignition must be off.
2. Activated charcoal filter system 81

FOX 2004
2.3.2 Test sequence

Remove the regeneration flexible hose-1- from the activated
charcoal filter in the electromagnetic valve 1 of the activated
charcoal filter -N80 - -2-.
Install the Vacuum pump -VAG 1390- or Vacuum pump -VAS
6213- as illustrated, the flexible hose-1-.
Operate the Vacuum pump -VAG 1390- or Vacuum pump -
VAS 6213 - several times. No vacuum can be generated.
If vacuum is generated:
Check the ventilation opening -3- in the lower part of the acti
vated charcoal filter -4- for impurities and, if necessary, clean
it.
If vacuum is not generated:
Cover the ventilation opening -3- and operate the Vacuum
pump -VAG 1390- or Vacuum pump -VAS 6213 - several times
again. Vacuum has to be generated.
If vacuum is not generated:
Replace the activated charcoal filter.
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
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

FOX 2004
3 Engine power electronic adjustment

(electronic accelerator)
Operation page 83 .
Engine power electronic adjustment (electronic accelerator)
page 84 .
3.1 Operation
The butterfly valve is not activated by a cable in the electronic
accelerator. There is no mechanical connection between the ac
celerator and the butterfly valve.
The position of the accelerator is transmitted to the Engine control
unit -J623- by two accelerator position sensors (variable resist
ance; stored in a case), which are connected to the accelerator.
The accelerator position (at the driver's criterion) is the main input
value for the Engine control unit -J623- .
The butterfly valve is activated by an electric engine (butterfly el
ement) incorporated to the Throttle
wage
n AG. Vobutterfly
lkswagen Avalve
G do command unit
es n
- J338- , in all load and
y Volkrotation
s intervals. ot g
u
b ara
ed
The butterfly valve
ho
ris is activated by a butterfly element, due
nte
to
e o the
data provided
s aut by the Engine control unit -J623- . ra
c
s
With the engine turned off and the ignition connected, the Engine
ce
le
un
pt
control unit -J623- activates the butterfly element, due to the data
an
d
itte
y li
provided by the Accelerator pedal position sensor -G79- . This

rm
ab
means that if the accelerator is half activated, the butterfly ele

pe
ility
ment will open proportionally, that is, the butterfly valve will be half
ot
wit
, is n
opened.
h re
hole
spec
With the engine running (loaded), the Engine control unit -J623-
es, in part or in w
may open or close the butterfly, regardless of the Accelerator

t to the co
pedal position sensor - G79- .

This way, the butterfly valve may, for instance, be completely
rrectness of i
open already, even if the accelerator is only half activated. The

advantage is avoiding losses for chocking, caused by the butterfly
l purpos
valve.
Also, this enables lower pollutant consumption and emissions for
nform
ercia
certain load conditions.

m
The necessary torque may be obtained by the Engine control unit

com
tion in
-J623- , through an optimum combination between the butterfly

r
te o
thi
valve opening and the over-supply pressure.

s
iva
do
r
Believing that the electronic accelerator comprises only one or

rp
cum
fo
two components would be a mistake. The electronic accelerator

en
ng
t.
yi
is a system comprised of all the components that contribute to
Co
op py
determine the position of the butterfly valve, in order to adjust it
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rig
and activate it, such as for example, Accelerator pedal position
py by
co Vo
sensor -G79- , Throttle butterfly valve command unit -J338- , "E-
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Prote
gas" system fault warning light -K132- , Engine control unit -
AG.
J623- , etc).
3. Engine power electronic adjustment (electronic accelerator) 83

FOX 2004
3.2 Engine power electronic adjustment (electronic accelerator)
1 - Pedal support
2 - Connector
Black, 6 poles
3 - Accelerator pedal position
sensor -G79- and Sensor 2 of
accelerator pedal position -
G185-
To remove, loosen the
AG. Volkswagen AG d
fastenings and discon ksw
agen oes
not
l
nect the connector.
by Vo gu
a
ed ran
ris
4 - 10 Nm tho tee
or
au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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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
r
rp
cum
fo
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara FOX 2004
ise nte
r
ut
ho 3 - Cyl. injectione o engine
ra - Edition 12.2009
s a c
s
ce
e
nl
pt
24 Supply system - fuel injection
du
an
itte
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erm
ab
ility
ot p
1 Injection system - repair
wit
, is n
h re
hole
General indications about the injection system
spec
es, in part or in w
t to the co
The Engine control unit -J623- is equipped with self-diagnosis.
Before carrying out repairs and troubleshooting, always check
the fault memory first. Likewise, check vacuum hoses and
connections (air infiltration).
rrectness of i
Minimum voltage of 11.5V is necessary for the perfect opera
l purpos
tion of electric components.

Do not use sealants with silicone. Silicone component resi
nf
ercia
o
dues aspired by the engine are not burned and damage the
rm
m
atio
Lambda Probe -G39- .
om
n in
c
Vehicles with airbag have a system for shutting off fuel in case
or
thi
e
of an accident. This system should prevent fire in the vehicle

t
sd
iva
after an accident by disconnecting the Fuel pump (pre-supply
o
r
rp
cu
pump) -G6- through the Fuel pump relay -J17- . At the same
o
m
f
en
ng
time, with this equipment, the engine starts more smoothly.

t.
yi Co
Cop py
t. rig
Fuel injection components - remove and install page 87 . opyri
gh by
Vo
ht
by c lksw
Intake manifold - remove and install page 89 . Prote
cted AG.
agen
Fuel distributor with injection valves - remove and install

page 90 .
Air filter set - disassemble and assemble page 90 .
Air filter set - remove and install page 91 .
Safety measures page 92 .
Cleaning rules page 65 .
Technical data page 94 .
1. Injection system - repair 85

FOX 2004
1.1 Component location
A - Brake pedal switch -F47- or

Brake light switch -F- AG. Volkswagen AG d
agen oes
olksw not
Together in one case, in ed by
V gu
ara
the feet compartment, horis nte
eo
on the brake pedal. aut ra
c
ss
B - Accelerator pedal position
ce
le
un
pt
sensor -G79- and Sensor 2 of
an
d
itte
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accelerator pedal position -
rm
ab
G185-
pe
ility
ot
At the feet compart
wit
, is n
h re
ment, on the accelerator
hole
pedal.
spec
es, in part or in w
C - Clutch pedal switch -F36-
t to the co
In feet compartment, on
clutch pedal.
rrectness of i
D - Fuel pressure regulator
l purpos
On the Fuel pump (pre-

supply pump) -G6- .
nform
ercia
1 - Magnetic valve 1 for activa

m
ted charcoal filter tank -N80-
a
com
tio
In the engine compart
n in
r
te o
ment.
thi
s
iva
do
2 - Intake manifold
r
rp
cum
fo
Remove and install.

en
ng
t.
yi Co
op py
3 - Knock sensor 1 -G61- t. C rig
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yri by
Installation location: On op Vo
by c lksw
engine block, intake cted agen
Prote AG.
side.
4 - Engine control unit -J623-
Below the lower wind
screen coating.
Remove and install.
5 - Engine speed sensor -G28-
Installation location: On engine block, intake side.
6 - Air intake temperature sensor -G42- with the Intake manifold pressure sensor -G71-
7 - Aeration hose valve
8 - Accelerator butterfly valve control unit -J338-
11 - Air Filter
12 - Oil pressure switch -F1-
13 - Lambda probe after the catalytic converter -G130-
14 - 4-pin connector
Black
To the Lambda probe -G39- Lambda probe heating -Z19- .
86 Rep. Gr.24 - Supply system - fuel injection

agen
AG. Volkswagen AG d
oes FOX 2004
ksw
by
Vol 3 - Cyl.
not
guinjection engine - Edition 12.2009
d ara
ise nte
or
15 - Lambda probe -G39-aut
h eo
ra
ss c
16 - Ignition coil 1 with final power stage -N70- , Ignition coil 2 with final power stage -N127- and Ignition coil 3
ce
le
un
pt
with final power stage -N291-
an
d
itte
y li
17 - Fuel distributor
rm
ab
pe
ility
ot
18 - Cylinder 1 injector - N30- , Cylinder 2 injector -N31- and Cylinder 3 injector -N32-
wit
, is n
h re
hole
spec
es, in part or in w
1.2 Fuel injection components - remove and install
t to the co
1 - Air filter set
rrectness of i
With filtering element.
l purpos
Disassemble and as
semble page 90 .
nform
ercia
Remove and install

m
page 91 .
a
com
tion in
2 - Duct for air aspiration
r
te o
thi
s
iva
3 - Injection valve harnesses.
do
r
rp
cum
fo
4 - Connector
en
ng
t.
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Black, 2 poles t. Cop py
rig
gh
From Cylinder 1 injec
ht
pyri by
Vo
tion valve -N30 - .
o
by c lksw
cted agen
Prote
AG.
tion valve - N31- .

tion valve - N32- .
5 - 10 Nm
6 - Fuel distributor with injec
tion valves
Remove and install
page 90 .
7 - 20 Nm
8 - 20 Nm
9 - Intake manifold
10 - Lambda probe -G39- , 50
Nm
Lubricate only the
thread with High-tem
perature paste -G 052
112 A3- ; High-tempera
ture paste -G 052 112
A3- should not enter in the grooves on the Lambda probe -G39- body.
Remove and install with the Socket set for Lambda probe -3337- .
11 - Connector
Black, 4 poles.
From Lambda probe -G39- .
12 - Lambda probe after the catalytic converter -G130 - , 50 Nm
Lubricate only the thread with High-temperature paste -G 052 112 A3- ; High-temperature paste -G 052
112 A3- should not enter in the grooves on the Lambda probe -G130- body, after the catalytic converter.
13 - Connector
Black, 4 poles.

FOX 2004
From Lambda probe after catalytic converter -G130 - .
14 - 10 Nm
Before removing, eliminate, if necessary, cooling system pressure.
2-pole connector.
16 - Sealing ring
Replace if damaged
17 - Retaining clip
Check for proper seating.
18 - 10 Nm
19 - Thermostat valve body n AG. Volkswagen AG do
swage es n
20 - Retaining clip byV
olk ot g
ua
d ran
Check for proper seating. ir se tee
tho
u or
a ac
21 - Coupling connector ss
ce
e
Connect or disconnect the connector with ignition switched off.

nl
pt
du
an
itte
y li
22 - Engine control unit -J623-
erm
ab
ility
In case of replacement, it is necessary to adapt the Engine control unit -J623- to the Immobiliser control
ot p
wit
unit -J362- Vehicle diagnosis, testing and information system VAS 5051.
, is n
h re
hole
23 - Spring clamp
spec
es, in part or in w
24 - Air duct
t to the co
25 - From head cover
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
FOX 2004 ra
s c
s 3 - Cyl. injection engine - Edition 12.2009
ce
e
nl
pt
du
an
1.3 Intake manifold - remove and install
itte
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erm
ab
ility
ot p
wit
, is n
1 - 10 Nm
h re
hole
spec
2 - Butterfly valve command
es, in part or in w
unit - J338-
t to the co
6-pole coupling connec
tor.
rrectness of i
Golden contacts.
Warmed Coolant.
l purpos
In case of replacement,
adapt the Engine control
nform
ercia
unit -J623- to the Butter
fly valve command unit - m
at
om
i
J338- Vehicle diagno
on
c
in t
sis, testing and informa
or
his
e
tion system VAS 5051.
at
do
priv
c
3 - Gasket
um
for
en
ng
t.
Replace.
yi Co
Cop py
ht. rig
4 - Coupling nozzle rig ht
py by
o Vo
For oil separator.
by c lksw
cted agen
Prote AG.
5 - Coupling nozzle
For the Electromagnetic
valve 1 for activated
charcoal filter -N80- .
6 - Sealing ring
Replace if damaged
7 - 20 Nm
8 - 3 Nm
9 - Intake manifold pressure
sensor -G71- with Air temper
ature sensor -G42-
4-pole coupling connec
tor.
Golden contacts.
10 - Sealing ring
Replace if damaged
11 - 20 Nm
12 - Sealing ring
Replace if damaged
13 - Intake manifold
14 - Intake nozzle

FOX 2004
1.4 Fuel distributor with injection valves - remove and install
1 - Fuel distributor with injec

tion valves
Check injection valves
for tightness and flow
page 95 .
2 - Sealing ring
Replace.
Quickly lubricate with
engine clean oil before
installation.
3 - For cylinder 1 injection
valve -N30 -
For cylinder 2 injection
valve -N31- .
AG. Volkswagen AG d
For cylinder 3 injection agen oes
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valve -N32- ed .
by
V gu
ara
is nte
Checkutinjection
ho
r
valves eo
for tightness
ss a and flow ra
c
page 95 .
ce
le
un
pt
an
d
4 - Retaining clip
itte
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rm
ab
Ensure proper seating

pe
ility
on injection valve and

ot
wit
, is n
fuel distributor.
h re
hole
5 - Drainage valve
spec
es, in part or in w
Drain the air

t to the co
page 78 .
6 - 10 Nm
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
1.5
iva
Air filter set - disassemble and assemble

do
r
rp
cum
fo
en
ng
t.
yi Co
op
Note C py
t. rig
gh ht
pyri by
Vo
o
For fastening the upper part of the air filter to the lower part, a
by c lksw
cted agen
number of self-tightening bolts are used. If these bolts are
Prote AG.
tightened or loosened with a power screwdriver, the thread on

the lower part of the filter can be damaged.
For that reason, a power screwdriver is allowed only if:
the power screwdriver speed does not exceed 200 rpm
a torque of 1.6 Nm at most is adjusted.

FOX 2004
1 - Upper part of filter air

2 - 1.6 Nm
3 - Filtering element
4 - Lower part of filter air
5 - 8 Nm
6 - Metal bonded rubber sup
port
7 - 5 Nm
AG. Volkswagen AG d
agen
8 - Rubber bearing Volksw
oes
not
gu
by ara
d
9 - Duct for air aspiration orise nte
eo
th
u ra
10 - Rubber bearing ss a c
ce
le
un
11 - Hose
pt
an
d
itte
y li
For engine cylinder
rm
ab
head cover.
pe
ility
ot
wit
12 - Clamp
, is n
h re
hole
Remove with VAS
spec
5024A or Standart type
es, in part or in w
clamp pliers -VW 5162- .
t to the co
13 - Air duct
To the Butterfly valve
rrectness of i
command unit -J338- .
l purpos
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
gh
1.6 Air filter set - remove and install
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

FOX 2004
1.6.1 Removal
Pull off intake air duct -1-.
Loosen spring clamp -2- with the VAS 5024A or Standart type
clamp pliers - VW 5162- and pull of air duct from the upper part
of filter air set.
Remove the left bolt fastening the air filter set -arrow-.
Tilt the Battery -A- cover forwards.
Move the air filter set upwards.
Remove air filter set.
1.6.2 Installation
Seat air filter set on the rubber supports -arrows-.
Press air filter set downwards onto the pins.
Tighten fastening bolts to 8 Nm.
Fasten the air duct with the spring clamp on the upper part of
the air filter set -2-.
Install intake air duct on intake nozzle-1-.
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
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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
1.7 Safety measures

rrectness of i
WARNING
l purpos
Fuel system is under pressure! Wear protective goggles and

clothing, so as to avoid serious injuries and contact with the
nf
ercia
skin. Before loosening tube junctions, place a cloth around the

or
union point. Then, eliminate pressure by pulling the flexible

m
m
atio
tube off carefully.

om
n in
or c
thi
te
sd
iva
To prevent injuries in people and/or destruction of the injection

o
r
rp
cu
and ignition system, take into consideration the following:

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

FOX 2004
For safety reasons, before opening the fuel system, remove

fuse number 33 from fuse holder, as the Fuel pump (pre-sup
ply pump) -G6- can be activated.
Do not touch nor disconnect ignition cables with the engine in
operation or upon start.
Only connect or disconnect the injection and ignition system
AG. Volkswagen AG d
cables, including measurement
lkswagen device cables,
oes with the ignition
not
switched off. d by Vo gu
a
e ran
ris t
If, in drive tests,
ut
ho it is necessary to use measurement and test
ee
or de
vices, consider
ss
a the following: ac
ce
le
The measurement and test devices must be fastened to the

un
pt
an
d
back seat and operated by another mechanic from then on.

itte
y li
rm
ab
If the measurement and test devices are operated from the front
pe
ility
ot
passenger seat, the person seating there could be injured by the
wit
, is n
passenger airbag being triggered, in case of an accident.
h re
hole
spec
To make the engine rotate with the starter, without running it:
es, in part or in w
t to the co
Disengage 4-pole connectors from Ignition coil 1 with final
power stage -N70- , Ignition coil 2 with final power stage -
N127- and Ignition coil 3 with final power stage -N291-
rrectness of i
-arrows-.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Disconnect coupling connectors -arrows- from cylinder 1 in
Co
op py
jector -N30- , cylinder 2 injector -N31- and cylinder 3 injector -
t. C rig
gh ht
N32- . yri
p by
o Vo
by c lksw
cted agen
Prote AG.
Remove fuse 33 from fuse holder.
1.8 Cleaning rules

To carry out fuel supply/injection works, consider the following 5
cleaning rules thoroughly:

FOX 2004
Carefully clean union points and respective surrounding areas

before separating thm.
Place parts on clean surface and cover them. Do not use
cloths that fray!
Carefully cover or close open parts, in case repair is not carried
out immediately.
Install clean parts only: Remove parts from the packaging im
mediately before installation. Do not use parts that have been
kept out of the packaging (for example, in tool boxes).
With system open: Do not work wit compressed air. Do not AG. Volkswagen AG d
move the vehicle. agen oes
o lksw not
V y gu
db ara
1.9 Technical data tho
rise nte
eo
s au ra
c
Engine identification letters s
BMD/CHFB
ce
le
un
pt
Idle speed check
an
d
itte
y li
erm
Idle speed operation 10) rpm 650...8709)
ab
ility
ot p
Engine control unit -J623- 11)
wit
is n
h re
System Simos 3PG8)
ole,
spec
Part number CPE (Electronic parts catalogue)
t to the co
Engine speed regime limit rpm from about 5800
rrectne
8) Simos 3 PG installed up to week 29, Simos 9.1 started in week 30.
s
9) Current values: Inspection of exhaust gases
s o
cial p
f
10) Not adjustable.
inform
mer
11) Remove and install Engine control unit -J623- page 102 .
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
co lksw
by
cted agen
Prote AG.

FOX 2004
2 Check components
Check injection valves page 95 .
Check fuel pressure regulator and residual pressure
page 98 .
2.1 Injection
wagevalves - check
n AG. Volkswa
gen AG
does
olks no t gu
yV
db ara
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Special ho and workshop
atools
eo
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equipment
ss required c
ce
le
un
pt
an
d
itte
(enc. 1/2") -VAG 1331-
y li
rm
ab
pe
ility
Remote control -VAG
ot
wit
1348A-
, is n
h re
hole
Auxiliary measuring cable
spec
set - VAG 1594C-
es, in part or in w
t to the co
Flow comparison meter -
VAG 1602-
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
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.1.1 Injection valve flow and tightness -

check
Fuel pressure must be OK page 98 .
Residual pressure and fuel pressure regulator - check
page 98 .
2. Check components 95
FOX 2004
2.1.3 Checking process

Remove 2-pole connector from the Cooling system tempera
ture sensor -G62- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V
Connect the Digital potentiometer d b (included at VAG 1594C) -
y gu
ara
se nte
VAG 1630- to 1+2 contacts thofo the connector for coolant tem
ri
eo
perature sensor -G62 - and
s a adjust the connected side to 15
u ra
c
kO. s
ce
e
nl
pt
du
Remove supply hose in the fuel distributor -1- and install it over
an
itte
y li
the oil separator -2- hose.
erm
ab
ility
ot p
Remove injection valve harness -3- from fuel distributor bear
wit
, is n
ings.
h re
hole
spec
Remove bolts fastening the fuel distributor-4-.
es, in part or in w
t to the co
rrectness of i
Disengage ignition coil connectors -5-.
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.
2.1.4 Tightness - check

Fuel distributor removed from cylinder head.
Keep a container below the injection valves with the connec
tors removed.
Ask someone else to operate the starter motor.
Fuel loss cannot exceed 2 drops a minute.
If the fuel loss is greater:

FOX 2004
Replace damaged injection valve page 90 .

Injection valves are installed in the reversed order. Please note
the following:
All of the injection valve sealing rings must be replaced and
slightly lubricated with clean engine oil.
Install the fuel distributor, with injection valves locked, on the
intake manifold and fasten it evenly.
2.1.6 Injection valve flow - check

Connect one injection valve contact, to be checked, to the
motor earth strap with Auxiliary measuring cable set -VAG
1594C- . AG. Volkswagen AG d
agen oes
olksw not
yV gu
Connect the other injection valve contact with Remote scontrol
ed b ara
nte
-VAG 1348/3A- and Adapting cable -VAG 1348/3-2-thoto the
ri
eo
Battery - A- positive terminal. ss au ra
c
ce
e
Turn ignition on; Fuel pump (pre-supply pump) -G6- must nl
pt
du
an
work:
itte
y li
erm
ab
Remove three graduated containers from the Flow compari
ility
ot p
son meter -VAG 1602- .
wit
, is n
h re
Remove fuel distributor from intake manifold.
hole
spec
Place the injection valve to be checked in a graduated con
es, in part or in w
t to the co
tainer.
rrectness of i
Remove the connectors from the injection valves that are not
being tested.
l purpos
Activate the Remote control -VAG 1348/3A- once more for 30

seconds.
nform
ercia
Do the same for the remaining injection valves.

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
cum
or
Use one graduated container for each injection valve.

f
en
ng
t.
yi Co
op py
After all injection valves have been tested, place graduated
t. C rig
gh ht
yri
containers over a flat surface and compare the injection flow. p by
o Vo
by c lksw
cted agen
Nominal value: 85...91 ml per each valve. Prote AG.
If the measured values of one or more injection valves are above

or below the nominal value:
Replace damaged injection valve.
FOX 2004
2.2 Residual pressure and fuel pressure regulator - check

equipment required
Pressure gauge -VAG
1318-
Adapting set -VAG
1318/17-
Connector -VAG 1318/23-
Remote control -VAG
1348A-
Adapting cable -VAG
1348/3-2-
lkswage es n
o ot g
byV ua
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
2.2.1 Pressure - check

rrectness of i
l purpos
Note
nf
ercia
The fuel pressure regulator establishes the approx. pressure

rm
m
of 3.0 bar for vehicles manufactured until May/2006 and 4.0

atio
m
bar for the ones produced as of June/2006.

o
n in
or c
thi
e
The fuel pressure regulator is on the Fuel pump (pre-supply

t
sd
iva
pump) -G6- .
o
r
rp
cu
o
m
f
en
ng
t.
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Co
Cop py
t. rig
gh ht
yri
Remove fuse holder cover. p by
co Vo
by lksw
cted agen
Prote AG.
G6- ) fuse holder.

FOX 2004
WARNING

tube off carefully.
Disconnect fuel hose coupling-1- and clean the spilled fuel

with a cloth.
Note
To unblock the fuel hose coupling, press the safety key.
Install the Pressure gauge -VAG 1318 - with the Adapters -

VAG 1318/9- and Adapting set -VAG 1318/17- .
Open the Pressure gauge -VAG 1318- valve. The valve indi
cates the flow direction.
Put fuse 33 ( Fuel pump (pre-supply pump) -G6- ) in the fuse
holder again.
Start engine and let it run in idle speed.
Measure fuel pressure. Nominal value: 3.0 bar for vehicles
manufactured until May/2006 and 4.0 bar for the
agen
AG.ones
Volkswpro
agen AG
does
duced as of June/2006. Volksw not
g y ua
db ran
If the nominal value is not obtained:
or
ise tee
th or
au
Turn the ignition off. ss ac
ce
le
un
Verify Fuel pump (pre-supply pump) -G6- page 77 check

pt
an
d
valve.
itte
y li
erm
ab
If nominal value is obtained:

ility
ot p
wit
is n

h re
ole,
spec
Check tightness and residual pressure (of the whole system).

To do so, check the pressure drop on the Pressure gauge -

t to the co
VAG 1318- . After 10 minutes, there must still be a positive

pressure of at least 2.0 bar.
rrectne
If retaining pressure drops below 2 bar:

Start the engine and run it at idle speed.
ss 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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
FOX 2004
Switch ignition off, after pressure has been created. At the

same time, it is necessary to close the Pressure gauge -VAG
1318- valve (valve transverse to the passage direction
-arrow-)
Check pressure drop on the Pressure gauge -VAG 1318- .
AG. Volkswagen AG d
If pressure keeps dropping: agen oes
olksw not
y V gu
d b ara
Check Pressure gauge -VAG 1318- pipes
orise to the Fuel pump nte
(pre-supply pump) -G6- . auth eo
ra
ss c
Check the tightness of the Pressure gauge -VAG 1318- .
ce
e
nl
pt
du
an
If the pressure does quit dropping:
itte
y li
erm
ab
Check sealing rings between fuel distributor and injection
ility
ot p
valves and the hose between Pressure gauge -VAG 1318- and
wit
, is n
fuel distributor.
h re
hole
spec
es, in part or in w
t to the co
Note
Before removing the Pressure gauge -VAG 1318- , place again
rrectness of i
cloths around the hose connections.
l purpos
2.2.3 Fuel pressure regulator - check
nform
ercia

m
at
om
ion
c
Retention valve for Fuel pump (pre-supply pump) -G6- OK,
in t
or
his
e
check page 77 .
at
do
priv
c
um
for
en
ng
t.
yi Co
Turn the ignition off. Cop py
t. rig
gh ht
yri
Remove fuse holder cover. p by
co Vo
by lksw
cted agen
Remove fuse 33 from the ( Fuel pump (pre-supply pump) - Prote AG.
G6- ) fuse holder.

Connect the Remote control -VAG 1348/3A- and Adapter ca
ble -VAG 1348/3-2- to the lower contact of fuse 33 for activat
ing the Fuel pump (pre-supply pump) -G6- and to the positive
terminal of Battery -A- (+).
WARNING

tube off carefully.
Loosen supply pipes -1- from fuel filter outlet.

Return pipes-2- (blue), keep connected.
Fuel filter-3- with inlet hose.

FOX 2004
Fuel supply pipes (from filter outlet to engine)-4-, connect to . Volkswage

AG
the measuring equipment outlet. ksw
agen
n AG d
oes
n ol ot g
yV ua
edb ran
ris tee
Note tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
Connect Pressure gauge -VAG 1318 - with Adapting set -VAG
pe
ility
1318/17- and Connector -VAG 1318/23- as illustrated.
ot
wit
, is n
h re
Close the valve on the Pressure gauge -VAG 1318- (trans
hole
verse valve in relation to the flow direction in position -B-).
spec
es, in part or in w
t to the co
Activate the Remove control -VAG 1348/3A- for approximately
10 seconds to fill up the fuel filter and generate system pres
sure of around 3.0 bar for vehicles manufactured until May/
2006, and 4.0 bar for those produced as of June/2006.
rrectness of i
Check pressure drop on the Pressure gauge -VAG 1318- . Af
l purpos
ter 10 minutes, the pressure cannot drop below 2.0 bar.

If the pressure keeps dropping:
nform
mercia
Check tube connections for leaks.
a
com
tion in
If no faults are found in the pipes:
r
te o
thi
s
iva
Replace fuel pressure regulator.
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
3 Engine control unit -J623-

Check and erase the fault memory in the Engine control unit -
J623- page 102 again.
Adapt functions and components page 104 .
3.1 Engine control unit -J623- - remove and

install
Before removing it, check identification and code
page 102 .
3.1.1 Removal
Remove windscreen wiper arms and lower windscreen cov
ering Electrical equipment; Rep. Gr. 92 ; Windscreen, rear
window and headlight wiper and washer .
AG. Volkswagen AG d
Disengage fitting connectors -arrows - from the Engine control
ksw
agen oes
not
unit -J623- . y Vol gu
db e
ara
ris nte
Move the Engine control unit -J623- to the frontuthpart
o of the eo
ra
vehicle. ss a 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
3.1.2 Installation
rrectness of i
Install the Engine control unit -J623 - until blocking it.
l purpos
Install fitting connectors for the Engine control unit -J623- .

Install the windscreen wiper arms and lower windscreen cov
nform
ercia
ering Electrical equipment; Rep. Gr. 92 ; Windscreen wiper

m
at
and washer, rear window and headlights .
om
ion
c
in t
Adjust the Engine control unit -J623- page 104

or
his
ate
do
Finally, refer to the fault memory of the new Engine control unit
priv
-J623- and, if necessary, erase the fault memory

um
for
en
g
page 102 .
n
t.
yi Co
Cop py
Perform a test drive.
t. rig
gh ht
pyri by
Vo
o
Check the fault memory in the Engine control unit -J623- . by c lksw
cted agen
Prote AG.
3.2 Check and erase the fault memory in the

Engine control unit -J623-

FOX 2004
Diagnosis, Measurement and Information System -VAS

5051A/52-
Vehicle diagnosis, measurement and information system -

VAS 5051A/52- with Cable -VAS 5051/1 - or Cable -
VAS 5051/3- .
Operation sequence
Connect the Diagnosis, Measurement and Information Sys
tem -VAS 5051A/52- as follows:
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
Connect with the Cable -VAS 5051/1- or Cable -VAS 5051/3-
y li
erm
ab
to the diagnosis plug.
ility
ot p
wit
Start the engine and run it at idle speed.
is n
h re
ole,
Only when engine does not run:
spec
Turn the ignition on.
t to the co
Select operation mode:
rrectne
Press Vehicle self-diagnosis on the display.
Select the vehicle system: ss o
Press 01 - Engine electronic system on the display.
cial p
f inform
The display shows the Engine control unit -J623- identification

mer
atio
and code.
om
n
c
Select diagnosis function:

or
n thi
te
sd
a
Press 02 - Check fault memory on the display.

iv
o
pr
cum
r
fo
If no faults are stored in the Engine control unit -J623- , the

en
ng
t.
yi
display shows 0 faults found.
Co
Cop py
t. rig
gh
If there are fault on the Engine control unit -J623- , they are
ht
pyri by
Vo
o
indicated on the display one after the other.
c by lksw
cted agen
Prote AG.
Press the key .
Press 05 - Erase fault memory on the display.
Press 06 - End test on the display.
3. Engine control unit J623 103

FOX 2004
3.3 Functions and components - adapt

Diagnosis, Measurement and Information System -VAS
5051A/52-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
Cable -VAS 5051/1- or Cable -VAS 5051/3- ss a ac
ce
e
nl
Operation sequence
pt
du
an
itte
y li
Connect the Diagnosis, Measurement and Information Sys
erm
ab
tem -VAS 5051A/52- -arrow-:
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
Connect with the Cable -VAS 5051/1- or Cable -VAS 5051/3-
m
atio
m
to the diagnosis plug.

o
n in
or c
Select, in the Diagnosis, Measurement and Information System -

thi
te
sd
a
VAS 5051A/52- the Assisted fault finding.

iv
o
r
rp
cu
o
After having checked all command units:

f
en
ng
t.
yi Co
op
Press the Skip key C py
t. rig
gh ht
yri by
Select Function/component selection cop Vo
by lksw
cted agen
Prote
Select drive
AG.
Select Engine identification letters

Select 01 - Systems with self-diagnosis
Select Engine distribution.
Select Functions
Select Function or component

FOX 2004
26 Exhaust system
1 Exhaust system components - re
move and install
Note
After installation works, make sure the exhaust system is not

tensioned and that there is a suitable distance from the body.
If necessary, loosen double and retaining clamps and align the
muffler and exhaust tube in a way that there is always a suit
able distance from the body and that the supports have a
uniform load.
Always replace self-locking nuts.
AG. Volkswagen AG d
agen
Volksw WARNING
oes
not
by gu
d ara
ise nte
Always replace uself-locking
thor
nuts and screws subject to angular eo
torque a ra
ss c
ce
e
nl
pt
du
an
itte
y li
Exhaust manifold, catalyst and front exhaust pipe with intermedi
erm
ate muffler and installation parts page 106 .0 ab

ility
ot p
wit
Rear muffler with supports page 107 .
, 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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Exhaust system components - remove and install 105

FOX 2004
1.1 Exhaust manifold, catalyst and front exhaust pipe with intermediate muffler
1 - Heat deflector AG. Volkswagen AG d

agen oes
Install without tension. olksw not
y V gu
d b ara
2 - 10 Nm rise nte
tho eo
au ra
3 - Exhaust manifold ss c
ce
e
nl
For removal, remove
pt
du
an
heat deflector and loos
itte
y li
erm
en front pipe.
ab
ility
ot p
4 - Lambda probe -G39- , 50
wit
, is n
Nm
h re
hole
spec
Lubricate only the
es, in part or in w
thread with High-tem
t to the co
perature paste -G 052
112 A3- ; High-tempera
ture paste -G 052 112
rrectness of i
A3- should not enter in
the grooves on the body
l purpos
of the Lambda probe -

G39- .
nform
ercia

the Socket set for Lamb
m
at
om
da probe -3337- .
ion
c
in t
r
In case of leakage, cut

o
his
te
and replace the sealing

a
do
riv
ring.
p
cum
for
en
g
5 - Gasket
n
t.
yi Co
op py
Replace.
t. C rig
gh ht
pyri by
Vo
6 - Heat deflector
co lksw
by
cted agen
Prote AG.
7 - Heat deflector
For Generator (Alterna
tor) -C- .
8 - 20 Nm
9 - Double clamp
10 - Tube
11 - For rear muffler
12 - Self-locking nut
25 Nm
13 - Front tube with intermediate muffler
14 - Intermediate muffler
15 - Sustaining handle
Replace if damaged
40 Nm
17 - Lambda probe after the catalytic converter -G130 - , 50 Nm
Lubricate only the thread with High-temperature paste -G 052 112 A3- ; High-temperature paste -G 052
112 A3- should not enter in the grooves on the Lambda probe -G130- body, after the catalytic converter.
In case of leakage, cut and replace the sealing ring.
106 Rep. Gr.26 - Exhaust system

FOX 2004
18 - Gasket
Replace.
19 - 10 Nm
25 Nm
1.2 Rear muffler with supports
1 - Exhaust back tube with muf

fler
2 - Sustaining handle
Replace when dam
aged.
Remove with the Hook -
VW 5812- .
3 - Separation point
Identified by a re-entry
on the connecting pipe.
As standard items, the n AG. Volkswagen AG do
rear muffler with ex lkswage es n
o ot g
haust tube as one part ed
byV ua
ran
are mounted. Forhrepair,
oris tee
the rear mufflerauis sup
t or
ac
plied individually with
ss
ce
le
one double clamp.

un
pt
an
d
itte
Separate perpendicu
y li
rm
ab
larly the connecting pipe

pe
ility
at the separation point

ot
wit
with one Pneumatic

, is n
h re
Saw -EQ 7415- or Pneu

hole
spec
matic Saw -VAG 1523A-

es, in part or in w
or Tube cutter -VAS

t to the co
6254- page 108

4 - Rear muffler
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Exhaust system components - remove and install 107

FOX 2004
Separation point on the exhaust tube
WARNING
Wear protection goggles and clothing to prevent from injuries

caused by metallic filings.
Cut exhaust tube in right angle on the -arrow 2- separation

point.
When installing, position the repair double clamp -4- on the
side marks-arrows 1 and 3-. Tightening torque 25 Nm.
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
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
108 Rep. Gr.26 - Exhaust system

FOX 2004
28 Ignition system
1 Ignition system - repair
General indications about the ignition system
The Engine control unit -J623- is equipped with self-diagnosis.
Minimum voltage of 11.5V is necessary for the perfect opera
tion of electric components.
In certain checks, the Engine control unit -J623- might identify
a fault and record it on the memory. For that reason, at the end
of all check and repair works, check the fault memory and
erase it, if necessary.
. Volkswagen AG
do gen AG
Ignition system components - removeVoand
lksw install page 109 . es not
a
y gu
db ara
Ignition coils with final power stages
ris
e - remove and install nte
page 110 . utho eo
ra
a c
ss
Safety measures page 111 .
ce
le
un
pt
an
d
Test data, Spark plugs -Q- page 112 .

itte
y li
rm
ab
1.1 Ignition system components - remove and install
pe
ility
ot
wit
, is n
h re
hole
spec
1 - Ignition coil 1 with power fi
es, in part or in w
nal stage -N70-
t to the co
Ignition coil 2 with power
final stage -N127-
rrectness of i
Ignition coil 3 with power
final stage -N291-
l purpos

Puller -T 10094-
nform
ercia
page 110 .
m
2 - Ignition coil connector

a
com
tion in
Black, 4 poles.
r
te o
thi
s
3 - Knock sensor 1 -G61- con

iva
do
r
nector
rp
cum
fo
en
g
Black, 2 poles.
n
t.
yi Co
op
Golden connector con
C py
t. rig
gh
tacts.
ht
pyri by
Vo
co lksw
by
cted
4 - 20 Nm
agen
Prote AG.
Tightening torque influ

ences Knock Sensor 1 -
G61- operation.
5 - Knock sensor 1 -G61-
Golden connector con
tacts.
6 - 10 Nm
7 - Connector
Black, 3 poles.
For Hall Sensor -G40- .
9 - Sealing ring
Replace if damaged
1. Ignition system - repair 109

FOX 2004
AG. Volkswagen AG d
agen oes
olksw not
10 - Connector d by V gu
ara
ise nte
Black, 3 poles. thor eo
au ra
For Oil level and temperature
ss sensor -G266- . c
ce
le
Not applicable.
un
pt
an
d
itte
y li
11 - Oil level and temperature sensor -G266- erm
ab
ility
Not applicable.
ot p
wit
is n
12 - 8 Nm
h re
ole,
spec
13 - Spark plug, 30 Nm
t to the co
Remove and install with Spark plug wrench -3122 B- .
Type and inter-electrode gap page 112
rrectne
1.2 Ignition coils with final power stages -
ss o
remove and install
cial p
f inform
mer
atio
om
Hook -T10118-
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
co lksw
by
cted agen
Prote AG.
Puller -T10094-
110 Rep. Gr.28 - Ignition system

FOX 2004
Removal
Install the Extractor -T10094- over the ignition coil with final
power stage.-arrow-
Install the Hook -T10118- as illustrated.
Unlock the connector block carefully and remove the connec
tor.
Remove ignition coil with final power stage.
Installation
Install the Extractor -T10094- over the ignition coil with final
power stage. gen AG
. Volkswagen AG
a does
lksw not
Install the ignition coil with final dpower
by
Vo stage in the -arrow- di gu
ara
rection on the engine cylinder or
ishead.
e nte
th eo
au ra
c
ss
Connect the connector to the ignition coil with final power
ce
le
stage until fitting it audibly.

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
1.3 Safety measures
nform
ercia
To prevent injuries in people and/or destruction of the injection

m
a
and ignition system, take into consideration the following:
com
tion in
Do not touch nor disconnect ignition cables with the engine in
r
te o
thi
operation or upon start.

s
iva
do
r
rp
Only connect or disconnect the injection and ignition system

um
fo
en
g
cables, including measurement device cables, with the ignition

n
t.
yi Co
switched off. Cop py
ht. rig
rig ht
If during a test drive, it is necessary to use test and measuring py by
co Vo
equipment, observe the following:
by lksw
cted agen
Prote AG.
The measurement and test devices must be fastened to the
back seat and operated by another mechanic from then on.
If the measurement and test devices are operated from the front
passenger seat, the person seating there could be injured by the
passenger airbag being triggered, in case of an accident.
To make the engine rotate with the starter, without running it:
Disconnect all 4-pole connectors -arrows- for the ignition coils.
1. Ignition system - repair 111

FOX 2004
Remove fuse 33 from fuse holder.
Note
Removing fuse 44, the voltage supply to the injection valves is

interrupted.
1.4 Test data, Spark plugs -Q-

Engine identification letters BMD/CHFB BMD/CHFB
Ignition order 1-2-3 1-2-3
Spark plugs 13) 12) BOSCH NGK
VW/Audi 101 905 601 B 101 905 617
Manufacturer reference F 7 HER2 ZFR5P-G
Inter-electrode gap 0.8...0.9 mm 0.8...0.9 mm
Tightening torque 30 Nm 30 Nm
12) Current values and replacement intervals of the Spark plugs -Q- : Exhaust
gas Test Folder.
13) Remove and install Spark plugs -Q- with Spark plug wrench -3122B- .
12.09 agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
112 Rep. Gr.28 - Ignition system

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Service

Service Department. Technical Information

Repair GroupsList of Workshop Manual Repair Groups ss c

15 - Cylinder head, valve control mechanism

All rights reserved.

Copyright 2010 Volkswagen AG, Wolfsburg BRA5R007520

10 - Cylinders, engine block, support, protector . . . . .ag. e.n A. G. ..Vo.lk.sw. a.g.en.A.G.do. . . . . . . . . . . . 3

1.1 Part I - Operating Poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Part II - Operating the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3 Crankshaft seal (flywheel side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

15 - Cylinder head, valve control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.3 Distribution times - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.1 Camshaft mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

20 - Supply system - tank, Fuel pump (pre-supply pump) G6 . . . . . . . . . . . . . . . . . . 62

24 - Supply system - fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2.1 Injection valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.2 Residual pressure and fuel pressure regulator - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

3 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.1 Engine control unit J623 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1 Exhaust system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

1.2 Rear muffler with supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1 Ignition system - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.1 Ignition system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

1.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1.1 Engine number

Additionally, there is sticker -arrow- with the engine identification

letters and theserial numberon the right engine support.

The engine identification letters are also indicated on the vehicle

1.2 Engine features

Identification letters BMD CHFB

2 Rep. Gr.00 - Technical data

10 Cylinders, engine block, support, protector

Special tools and workshop

Torque wrench - 40 to 200

ation sequence below. Check if the vehicle has code radio. If

positive, request the anti-theft code before disconnecting earth

strap from the Battery -A- .

placed in the same position again during engine installation.

Remove air filter set page 91 .

Eliminate pressure, pulling the tube carefully.

Remove vacuum and vent hoses from the engine.

switch -F18- and from the Radiator fan -V7- .

Remove fastening screw from front exhaust tube support strap

Loosen front exhaust tube from catalytic converter

1. Engine - remove and install 5

Remove transmission pendulum support -arrows-.

Remove the Poly-V belt page 13 .

Vehicles with air conditioning

Remove air conditioning compressor: Aeration system;

Rep. Gr. 87 ; Air conditioning and anchor to the body with a

Use safety pins on fitting hooks and pins so as to prevent dam

Positions numbered 1...8 on suspension bar face the pulley

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

Remove power-drive group support, engine-arrows-.

Remove power-drive group support, transmission -arrows-.

1.2 Additional notes and assembly works in

To avoid damage to the condenser and cooling gas hoses, do not

kink, twist nor overstretch the hoses.

Remove the Poly-V belt page 13 .

1. Engine - remove and install 7