Volkswagen FOX 2004 User Manual

Service

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4c - Cyl. diesel engine

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Engine ID

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Edition 08.2010

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Service Department. Technical Information

Service

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00 - Technical datat p

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10 - Cylinders,is

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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 BRA5R007820

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																		s																										a			Fox 2004
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																		s										4 - Cyl. diesel engine - Editionc08.2010
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00 - Technical data . . . .is				n																																																					i			1
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1	Technical data		e																																																								s	1
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	Engine numberi .			.		.				.			.		.		. .	. . . .	.		.	.	.	.	. .		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.			. . .	. . .	.		.			.	.			.c. .
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1.2	.Engine featurest			.		.				.		.			.		. .	. . . . .	.		.	.	.	.	.		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.		.	. . .	. .	.				.		.			. .h.	1
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		a									support, protector																																																c	2
10 - Cylinders, engine block,,																											.	. .	. . . .	.	. .	.	.		.		.	.	.			.	.		.		.	. .	. .	.					.			.	. .e
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	Engine - removes and install . . .																		. .		.	.		. .	.	.	. .	. . .	. . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.				.		.			. . t.
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	Notes on removal					. .					.		.		.		.	. . . . .	.		. .	.		. .	.	.	. .	. .	. . . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.				.		.			. .s.
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1.2	Fasten the	engine on assembly stand																					.	.	. .		. .	. . .	. . . .	. .	.	.	.	.	.	.		.	.		.		.	.	.		.	. . .	. .	.				.		.			. .n.	6
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1.3	Notes on installation																																																											7
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1.5			o										-drive group																																													n	o	8
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1.6	Additional notes and installation works in vehicles with air conditioning																																																				s			. . . .				9
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13 - Crankshaft, pistons												p																																					e.m											11
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	Engine - disassemble and assemble																					.	.	.	. .		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.		.		. . .	.				.		.			. . .
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1.2																				y				pulley - check														k.l					b																	17
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2.1	Crankshaft sealing (pulley side) - replace																								.	.	.	. . .	. . . . .	.	. .	.	.	.		.	.	.	.		.		.	.	.		.	. . .	. .	.				.		.			. . .	20
2.2	Crankshaft flange (pulley side) - remove and install . . .																													.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.				.		.			. . .	23
3	Crankshaft - remove and install																		.		. .	. .		. .	.	.	. .	. .	. . . . .	. .	.	.	. .		.	.	.		.	.		.	.	.	.			. . .	. . .	.					.	.			. . .	26
3.1	Crankshaft measurements																	. . . .	. .		.	. .		. .	.	.	. .	. . .	. . . .	. .	. .		. .		.	.	.	.	.		.		.	.	.			. . .	. . .	.	.			.		.			. . .	27
4	Pistons and connecting rods - remove and install																												. . . .	. .	.	.	. .		.	.	.		.	.	.		.	.	.			. . .	. . .	.	.				.	.			. . .	28
4.1	Piston protrusion - check																.	. . . .	. .		.	. .		. .	.	.	. .	. .	. . . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	31
4.2	Piston and cylinder dimensions																		. .		.	. .		. .	.	.	. .	. . .	. . . .	. .	.	.	. .		.	.	.		.	.	.		.	.	.			. . .	. . .	.	.				.	.			. . .	32
15 - Cylinder head, valve control mechanism																									.		. .	. .	. . . .	.	. .		.	.	.		.	.	.				.		.		.	. .	. .	.	.				.			.	. .	33
1	Cylinder head - disassemble and assemble																										.	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.		.	. .	. . .	.	.			.		.			. . .	33
1.1	Toothed belt - remove and install, adjust																								. .		. .	. . .	. . . .	. .	.	.	.	.	.	.		.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	36
1.2	Cylinder head - remove and install																				.	. .		. .	.	.	. .	. . .	. . . .	. .	.	.	. .		.	.	.		. .		.		.	.	.			. . .	. . .	.	.				.	.			. . .	42
1.3	Compression - check												.		.		. .	. . . .	. .		.	. .	.	.	. .		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.			. . .	. . .	.	.			.		.			. . .	48
2	Valve command - repair																.	. . . . .	. .		.	. .		. .	.	.	. .	. . .	. . . .	. .	. .		. .		.	.	.	.	.		.		.	.	.			. . .	. . .	.	.			.		.			. . .	50
2.1	Valve seat - grind				.	.				.			.		.		.	. . . . .	. .		.	. .		. .	.	.	. .	. .	. . . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	52
2.2	Valve guides - check											.			.		. .	. . . . .	.		.	. . .		.	.		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.		.	. .	. . .	.	.			.		.			. . .	54
2.3	Valve stem seal - replace																	. . . . .	. .		.	. .		. .	.	.	. .	. .	. . . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	55
2.4	Camshaft - remove and install .																		. .		.	. .		. .	.	.	. .	. . .	. . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	57
2.5	Hydraulic tappets - check																	. . . . .	. .		.	. .		. .	.	.	. .	. .	. . . . .	.	. .	.	.	.	.		.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	60
17 - Lubrication system			.	.		.					.		.				. .	. . . .	.		.	. .		.	.	.	.	. . .	. . .	. .	.	.	.		.	.		.	.		.		.	.			.	. .	. .	.	.				.			.	. .	61
1	Lubrication system components - remove and install .																													. .	. .		. .		.	.	.		.	.			. .		.		.	. . .	. .	.	.			.		.			. . .	61
1.1	Crankcase - remove and install																		. .		.	. . .		.	.		. .	. . .	. . . .	. .	. .	.	.	.		.	.	.	.		.		.	.	.		.	. .	. . .	.	.			.		.			. . .	65
1.2	Oil pressure and Oil pressure switch F1 - check .																												. . . .	. .	. .		. .		.	.	.		.	.			. .		.		.	. . .	. .	.	.			.		.			. . .	68
19 - Cooling system		. .	. .			.			.			.			.		.	. . . .	.		.	. .		. .	.		. .	. .	. . . .	.	.	.	.	.		.		.	.		.		.	.			.	. .	. .	.	.				.			.	. .	71
1	Cooling system components - remove and install																												. . . . .	.	. .	.	.	.		.	.	.	.		.		.	.	.		.	. . .	. .	.	.			.		.			. . .	71
1.1	Cooling system components in the body																								. .		. .	. . .	. . . .	. .	.	.	.	.	.	.		.	.		.		.		.		.	. . .	. .	.	.			.		.			. . .	72
1.2	Cooling system components in the engine																									.	. .	. .	. . . . .	. .	.	.	. .		.	.	.		.	.		.	.	.	.			. . .	. . .	.	.				.	.			. . .	73

1.3Cooling hose connection diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.4	Cooling system - drain and fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75
1.5	Water pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
1.6	Radiator - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81

Contents i

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

1.7 Thermostat valve - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

20 - Supply system - Fuel tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		85
1	Fuel supply system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
1.1	Fuel tank with accessories - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
1.2	Fuel filter - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
1.3	Safety measures when working in the supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
1.4	Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
1.5	Fuel tank - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
1.6	Fuel level indicator sensor G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
1.7	Fuel level meter - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
1.8	Engine power electronic adjustment (electronic accelerator): check . . . . . . . . . . . . . . . . . .	94

23 - Supply system - mechanical injection (diesel)																			.	.		.	.		.		.		.	.	.		. .	. . . .	.	. .			.	.	.		.	.		.	.	.		.	.			95
1	Direct diesel injection system - repair												.	. .	.	. . .	.	.		.	.	.	.		.		.	.	.	.	.	.	.	. . . . .	. .	.	.		. .		.	.	.	.	.		. .		.	.		.		95
1.1	Safety measures . . . . . . . .	.	. . .		.			.	.			.		. .	. .	. .	.	.	.		.	.	.		.		.	.	.	.	.	.	.	. . . . .	.	. .	.		.	.		.	.	.	.		. .		.	.		.		95
1.2	Cleaning rules . . . . . . . . . .	.	. . .		.			.	.			.		. .	. .	. .	.	.	.		.	.	.		.		.	.	.	.	.	.	.	. . . . .	.	. .	.		. .			.	.	.	.		. .		.	.		.		95
1.3	Injector pump - repair . . . . .	.	. . .		.			.	.			.		. .	. .	. .	.	.	.		.	.	.		.	.		.	.	.	.	.	G...	V .o.lk.sw.	a.g.	e.n.			. . .			.	.	.	.		. .		.	.		.		96
1.4	Intake manifold - remove and install																										w.a.g												G.d.o															98
												.		. . .	.	. .	.	.	.	.		.	.	.		.					.	.		. . . .				.				.	.	.	.		. .		.	.		.
																									s					en		A					A					e	s	n
																								lk																					ot
1.5	Injector pump - remove and install																			b			o																								g.u							99
							.		.			.		. .	. .	. .	.	.	.			V. .			.	.		.	.	.	.	.	. .	. . . .	. .	. .			. . .			.	.	.					.	.		.
																			d		y																										a
1.6	Injectors - remove and install															o		e																														r			e.			103
		.	. .		.		.		.		.		.	.	. .			. .			.	.	.		.	.		.	.	.	.	.	. . .	. . .	. .	. .			. . .			.	.	.	.		. .		a. .
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1.7	Injectors - check															th																																						105
		. .	. .			.	.		.		.		.	.	. .s	. . .		. .			.	.	.		.	.		.	.	.	.	.	. . .	. . .	. .	. .			. . .			.	.	.	.		. .		.	.		.
																u																																					o
																																																						r
															a																																							a
														s																																								c
																- replace																																							c
1.8 Sealing ring on the injection regulator covern																								.		.		.	.	.	.	.	. . .	. . .	.	. .	.		. .		.		.	.	.		. .		.	.		.		106t
														le																																									e
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2	Engine control unit J623											e	d																																									107		a
										i																																																	a
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									m				install																																									107					i
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2.1 Engine control unit J623 - remove ande																		.	.		.		.	.		. .			.	.	.	.	. . .	. . .	.	. .	.		. .		.		.	.	.		. .		.	.		.
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2.2 Engine control unit J623 fault memoryn												- read and clear																																										107												t
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2.3			s																																																			108													e
	Functions and components - adapt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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26 - Exhaust system			h																																																		110														e
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			i																																																																o
1			r																																																			110
	Removing and installing exhaust system parts .																	. .			.		.	.	.	.			. .	.		. .	. .	. . . .	.	. .		.	. .			.	.	.	.		. .		.	.		.
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		r																																																				110
1.1 Exhaust system - remove and install											.		.	. .	.	. . .		. .		.		.	.	.		.		.	.	.	.	.	. . .	. . .	. .	. .		.	. .			.	.	.	.		. .		.	.		.															r
		a																																																																	c
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2	Exhaust gas return system	i																																																				113
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		s						- remove and install																																														113													n
2.1 Exhaust return system componentsp																												.	.	.	.	.	. . .	. . .	.	. .	.		. .		.		.	.	.		. .		.	.	.																s
		o																																																																	e
		r																																																				114													s
2.2 Connection plan for vacuum hoses									.		.		.	. .	.	. . .		. .			.	.	.		.	.		.	.	.	.	.	. . .	. . .	.	. .	.		. .	.			.	.	.		. .		.	.	.																o
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2.3 Check exhaust gas return valvec .						.	.		.		.		.	.	. .	. . .		. .			.	.	.		.	.		.	.	.	.	.	. . .	. . .	. .	. .			. . .	.			.	.	.		. .		.	.	.																f
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28 - Chamber pre-heating system			e																																																		116														m
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1.1	Pre-heating plugs - check							t																																														116						d	s	i
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																																			.G

ii Contents

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

00 – Technical data

1Technical data

1.1Engine number

Engine number (“engine identification letters” and “serial num

ber”) is engraved on the engine block, at the engine/transmission

separation area.

digits.

Theenginenumberhasamaximumofnine(alphanumeric)a

o

G.

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ag

enA

en

g

The first part (max. of three identification letters) represents the

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“engine identification letters”; the second part (six characters)

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b

d

e

is

representsthe“serialnumber”.Ifmorethan999,999engineswith

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o

th

thesameengineidentificationletterssareproduced,thefirstofthe

u

six digits is replaced by a letter.

l

a

s

n

e

d

u

Additionally, there is a sticker onitt

the mechanical distribution up

m

e

letters” and “the serial

per cover with “the engine identificationr

number”.

t

p

e

o

n

are also shown on the vehicle

e

The engine identification letters,

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t

i

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h

data plate.

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c

1.2

e

Engine featuresr

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a

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p

ASY

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Engine identification letters

e

n

r

i

r

,

Production

s

.11.01

c

o

e

e

t

s

n

Cylinder volume

p

3

1896

s

u

o

r

cm

s

p

f

l

EU 3 Norm

i

gas limit values

o

According to the exhaustr

i

n

a

f

c

r

Power

hp(kW)/rpm

m

e

m

t

m

i

Torque

o

Nm(mkgf)/rpm

o

r

125,0(12,7)/1600in

o

n

Diameter

c

t

Ø mm

79,5

i

s

h

t

a

e

Stroke

p

mm

95,5 c

o

d

r

v

i

u

Compression rate

r

m

f

n

o

19,5:1n

g

e

i

t

p

.

C

CZ

y

at least

p

49

C

o

.

o

y

r

Knock control

t

ry

h

b1 knock sensor

g

g

h

i

i

p

o

c

y

t

Self-diagnosis

y

det

gaw

o

yes

kl

b

c

et

s

or

e

P

n

A

Catalytic converter

.G

yes

Exhaust gas return

yes

1. Technical data 1

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

10 – Cylinders, engine block, support, protector

1Engine - remove and install

Special tools and workshop equipment required

♦Suspender or VW 055 -2024A-

♦Support -T 10012-

♦Support for VW 643 or VW 643/1 -VW 313or Rotary stand for engine and trans mission - VAS 6095-

♦Support -VW 540-

♦Hydraulic hoist - V.A.G 1202 A-

♦Oil collecting tray -VAG

1306-

♦Torque wrench - 5 to 50Nm (enc. 1/2") -VAG 1331-

♦Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-

b

d

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e

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or

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A

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	i	h

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

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

♦Transmission jack or en gine + transmission set - VAG 1383A-

♦Standart-typeclamppliers- VW 5162 (VWB) - ou - VAS 5024A-

♦5-step ladder -VAS 5085-

♦Grease -G 000 100-

♦Screw M10×25 / 8.8

♦Cable tie

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1.1		m
	Notes on removal
		o
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– The engine is removed from below, together with the trans
		a
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mission.		r
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For installation works, especially in the engine compartment,det
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				b	c
due to reduced existing space, consider the following:					et	or
						P

♦All hoses (e.g.fuel, hydraulics, activated charcoal filter system, cooling system and cooling gas, brake fluid, vac uum) and electric cables must be restored to their original positions.

♦Provide easy access to all the moving or hot parts.

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										.
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–All the cable ties loosened or cut to remove the engine must be reinstalled at the same points upon installation.

1. Engine - remove and install 3

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

en

g

a

w

s

lk

o

V

y

b

Note

d

o

e

is

r

th

u

a

s

During the work sequence, the Battery -A- earth strapl

will have

s

n

e

to be disconnected.Therefore, check first whetherd a code radio

u

is installed.If so, first obtain the anti-theft systemi

e

t

code.

m

t

p

e

r

t

Battery -A- earth

– With the ignition switched off, disconnect then

strap.

o

,

s

i

e

l

relievethepressure

– Openandclosecoolantreservoircovertow

in the cooling system.

h

i

n

r

o

– Remove the battery -A- and the batterya support -A- .

t

r

p

– Remove the connection hose betweensthe air filter and the

n

i

intake air duct.

,

s

e

– Remove air filter.

o

u

p

r

p

– Remove the lower noise insulation fromrthe engine.

l

a

i

c

e

– Remove the drive semi-shaft on the right side and loosen the

m

one on the left side of the transmission.

Running gear; Rep.

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m

o

Gr. 40 ; Front suspension .

c

e

o

		t
		a
– Lift the left drive semi-shaft and tie it on the anti-roll bar.
		v
		i
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		p
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– Remove the front part of the exhaust tube with theicatalytic
		f
		g
	converter page 110 .	n
		o
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		.
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–	Drain the cooling system page 75 .	h	y
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			i
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						c
						y
–	Remove the hoses from the engine with Standart-Type clamp						b	ce
								d
	pliers -VW 5162 (VWB) - ou - VAS 5024A- .							et

AG.

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olk

swagen

AG

does

not

guarant ee

or a c c e p t a

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–Also remove the lower hose in the radiator -arrow- .

–Disconnect and release all the transmission electric connec tions, Generator (Alternator) -C- and Starter -B...- .

–Disconnect all the fitting, cooling, vacuum and intake hoses from the engine.

–Loosen the clutch hydraulic receiver cylinder: Automatic / mechanical transmission; Rep. Gr. 30 ; Clutch - command system .

–Loosen the transmission gearshift lever: Automatic/me chanical transmission; Rep. Gr. 34 ; Drive, housing .

WARNING

♦Boththefuelandthefueltubesmaybecomeveryhot(risk of burns)!

♦In addition, the fuel system is under pressure! Before openingthesystem,placeaclothonthefittingandrelieve the pressure by carefully loosening it!

♦Alwaysusegogglesandglovesinalltheinstallationworks in the fuel system!

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

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

o

G.

V

lksw

ag

– Disconnect the fuel supply andAreturn tubesen-arrows- on the

en

A

G

d

injector pump.

g

o

a

e

w

s

s

n

lk

ot

o

V

g

y

u

b

d

a

e

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is

a

n

r

– Seal the tubes so as to prevent any dirt from entering the supt

ply system.

o

e

th

e

or

u

a

a

s

c

s

c

le

e

p

– Follow cleaningn

rules page 89 .

t

e

d

u

and loosen the remaining electrical connectors

a

t

– Disconnectit

m

engine.

frome ther

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p

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s

i

,

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o

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n

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o

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– rRemove the pendular support -arrows-.

a

p

n

i

,

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e

s

o

p

r

u

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l

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i

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r

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m

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.

1.1.1

Vehicleth

with air climate control:

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page 15 .

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V

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– Remove the Poly-V beltb

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et

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P

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– Observe additional indications and assembly works

page 9 .

– Remove Generator (Alternator) -C- .

1.1.2Continued for all vehicles.

–Install the Support -T 10012on the Transmission jack or en gine + transmission set -VAG 1383A- .

–By using the fastening nut and the M10×25/ 8.8 screw, install theSupport-T10012-ontheengineblockwithapprox.40Nm.

–Lift slightly the engine and the gearbox using the Gearbox or Engine + gearbox combo jack -VAG 1383A- .

t o

t

1. Engine - remove and install 5

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

–Loosen, from above, the subframe by the engine supporting side -arrows- .

Note

To remove the fastening screws, use the 5-step ladder -VAS 5085- .

–Loosen, from above, the subframe by the transmission sup porting side -arrows-.

–Carefully lower the engine with the transmission.

o

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enAG

g

a

Note

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b

o

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is

r

Carefully, lower the engine and the transmission in order to pre

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th

vent damages to the body.

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le

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d

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t

o

n

1.2

on assembly stand

Fasten the enginee,

s

i

l

o

h

To perform assembly works, itwis necessary to fasten the engine

on the Transmission jack or enginer

+ transmission set -VAG

i

1383Aor Support -VW 540-r.

o

t

a

1.2.1

p

Sequence ofs operations

n

i

,

e

– Release the transmission.p

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h

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

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

1.2.2Continued for all vehicles.

–Raise the Suspending device or VW 055 -2024A- as follows and remove it from the Transmission jack or engine + trans mission set -VAG 1383A- , by using the Hydraulic winch - V.A.G 1202 A- .

Pulley side: position 4 of the vertical rod. Orifice on the sustaining bar in position 2

Steering wheel side: position 3 of the vertical rod. Orifice on the sustaining bar in position 8

WARNING

wa

ge

AG

s

n

lk

o

V

y

Use safety locks on the hooks and pins -arrows-. r

b

d

e

is

o

th

u

a

s

s

le

d

u

n

e

Note

t

t

m

i

r

p

e

t

the supporting bar re

♦ Alignment positions marked as 1...8 onn

main faced to the pulley.

,

s

i

e

l

o

from the hook.

♦ The holes in the vertical rods are countedw

h

n

i

r

o

– Fasten the engine with the Support for VW 643 or VW 643/1

t

r

and transmission -VAS

-VW 313or Rotary stand for enginep

6095- .

a

s

n

i

,

e

s

1.3

o

Notes on installationp

p

r

u

l

Install by inverting the removal sequence, paying attention to the

a

i

following:

c

m

r

e

m

– Check clutch bearing for wear and replace it, if necessary.

o

c

r

o

– Slightly lubricate the clutch roller bearing, the roller bearing

e

t

a

guide bushing and the primary shaft splinesr with Grease -G

v

i

r

000 100- .

p

g

o

f

n

i

y

– Check whether there are coupling guides for engine/transmisC

p

o

sion on the engine block and install them, if necessary.i

.

t

h

g

r

y

p

o

– When installing the subframe, pay attention to the mobilitybd in

c

y

et

relation to the drive semi-shafts.

c

P

et

or

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

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w

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s

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c

o

r

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e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

o

c

u

m

e

n

t

.

C

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p

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i

g

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b

y

V

o

kl

s

w

a

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e

A

n

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Note

Tightening torques for the subframe pads page 8 .

–Align the engine without tension by moving and occasionally loosening the engine support also on the body.

–Install gearshift lever: Automatic/mechanical transmission; Rep. Gr. 34 ; Drive, housing .

–Install the clutch hydraulic receiver cylinder: Automatic / mechanical transmission; Rep. Gr. 30 ; Clutch - command system .

–Remove cooling and vacuum system hoses.

1.3.1Vehicles with air conditioning

–Install the air conditioning compressor: Aeration system ; Rep. Gr. 87 ; Air conditioning .

1. Engine - remove and install 7

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

– Install the Generator (Alternator) -C- .

1.3.2Continued for all vehicles.

–Install Poly-V belt page 15 .

–Electrical connections and their positions: Electrical equip ment; Rep. Gr. 97 ; Cables and wiring harnesses .

–Installthefrontpartoftheexhausttubewithcatalyticconverterpage 110 .

–Fill cooling system page 75 .

–Perform a test drive and check fault memory page 107 .

1.4Tightening torques

Location

o

Tightening tor

en

AG.V lkswagequen

A

g

G

d

o

a

e

w

s

s

n

Screws and nuts

lk

M6

10 Nm

ot

o

V

g

y

u

b

d

a

e

r

s

M7

15 Nm

a

i

n

r

t

o

ee

th

o

u

M8

25 Nm

r

a

a

s

c

s

c

le

e

p

n

M10

40 Nm

u

t

d

a

t

e

n

t

M12

60 Nm

y

i

l

m

i

r

a

e

b

i

p

fastening

M10

45 Nm

l

i

t

y

Engine to transmissiont

w

screws

s

n

o

i

t

h

i

r

,

e

e

fastening

M12

80 Nm

s

l

p

Engine to transmissiono

screws

h

e

w

c

t

n

40 Nm

t

i

o

r

Drive shaftso and flanges

t

t

h

e

r

40 Nm

a

c

p

o

Exhaust tube

n

r

r

i

,

e

s

c

e

t

n

s

o

e

p

s

Noter

s

u

o

p

f

l

i

a

n

i

c

f

Subframe tightening torques page 8 .

o

r

e

r

m

m

a

m

1.5

for the power-drive group

i

o

in

o

c

Supportsr

t

n

o

e

s

i

h

t

d

a

v

o

i

1.5.1

r

torques

c

p

u

r

em

o

Tighteningfg

n

n

i

t

y

.

C

p

o

o

WARNING

C

p

y

.

t

r

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i

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V

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a

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et

g

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n

Before loosening the screws, the subframesor

must be fastenedA

with Support or VW 061 -10-222A-

P

.G

WARNING

Alwaysreplaceself-lockingnutsandscrewssubjecttoangular torque

8Rep. Gr.10 - Cylinders, engine block, support, protector

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

Power-drive group support, engine A1) = 20 Nm + 90°.

B1) = 30 Nm + 90°.

1) Replace

Power-drive group support, transmission

o

A

= 40 Nm + 90°.

G.

V lksw

ag

2)

swa

en

genA

lk

o

V

B

2)

= 50 Nm + 90°.e

y

d

b

is

r

o

2) Replace.

th

u

a

s

s

le

d

u

n

e

t

t

m

i

p

e

r

t

o

n

s

i

,

e

l

o

h

w

n

oPendular support

i

r

AG

does

not

guarant ee

or a c c e p t a

n y

l i a

t

pA = 30 Nm + 90°.

r

a 3)

n

eB = 40 Nm + 90°.

i

s 3)

,

s

3) Replace.

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

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o

s

a

e

t

d

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o

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i

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p

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m

f

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1.6

n

Additional notes and installation workso

n

i

t

p

.

C

y

o

p

C

with air conditioning

t

in vehiclesgir

y

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r

t

h

g

y

h

i

b

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c

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b

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WARNING

A

n

P

.G

Air conditioning cooling gas circuit should not be opened.

e c t

Note

To avoid damages on the condenser and refrigerant gas tubes/ hoses, make sure the latter are not twisted, bent or excessively stretched.

To be able to remove and install the engine without opening the cooling gas circuit:

–Remove cooling gas hose clamp(s).

–Remove the Poly-V belt page 15 .

1. Engine - remove and install 9

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

–Remove Generator (Alternator) -C- .

–Remove air conditioning compressor Aeration System; Rep. Gr. 87 ; Air conditioning .

–Fasten the compressor to the body so that the cooling gas tubes/hoses are not under tension.

10

.

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

b

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Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

13 – Crankshaft, pistons

1Engine - disassemble and assemble

Note

♦To perform assembling works, fasten the engine on the as semblystand,usingtheSupportforVW643orVW643/1-VW 313-orRotarystandforengineandtransmission-VAS6095-.

♦It is necessary to carefully clean the oil ducts and to replace the oil filter if, when servicing the engine, significant amounts of metal particles and detached particles are found in the oil, due to abrasion or wear resulting from seizing (for instance from the connecting rods or bearing shells).This procedure avoids damage.

♦Beforeperformingassemblyworks,itisnecessarytolubricate support and sliding surfaces.

.

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a

w

s

lk

o

V

WARNING

is

y

b

d

e

r

o

th

u

toangular

Alwaysreplaceself-lockingnutsandscrewssubjects

a

torque

le

s

e

d

un

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

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h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

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m

m

o

c

r

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t

a

v

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C

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1. Engine - disassemble and assemble 11

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

							m	i	t
						r
				p	e
			t
		o
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i
,
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							v

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Part I

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12 Rep. Gr.13 - Crankshaft, pistons

							.V
						enAG
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				a
			w
	yV4 - Cyl. diesel
		s
	lk
	o
	b
	d
	e
	is
1 - 10 Nm + 90°	r

Replace after each re moval.

2 - Pulley/ vibration damper

The installation is only possible in one position (displaced holes).

3 - 25 Nm

4 - Tensioning element for Poly-V belts

5 - Compact support

When installing, pay at tention to the coupling guide centering.

To the Generator (Alter nator) -C- .

In case of additional ac cessories with air condi tioning compressor.

6 - 45 Nm

7 - Generator (Alternator) -C-

8 - 25 Nm

9 - Poly-V belt

Mark direction of opera tion before removing.

Check for wear.

Do not bend.

Remove and installpage 15 .

Part II

olkswagen

engine -

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	d
	o
	e
Editiono08.2010tg
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			t
	s	i	h

1. Engine - disassemble and assemble 13

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

1 - 45 Nm

2 - Engine support

3 - Mechanical distribution up per cover

4 - Toothed belt

Mark the rotation direc tion before removing.

Check for wear.

Do not bend.

Remove and install, ad just page 36 .

5 - 25 Nm

6 - 25 Nm

Adjust the toothed beltpage 36 .

7 - 20 Nm

8 - 45 Nm

9 - Camshaft gear

Toothed belt - remove and install, adjust

page 36 .

10 - Tensioning pulley

Installation positionpage 15

Check page 17 .

11 - Pulley

12 - Injector pump gear

13 - 10 Nm

14 - 30 Nm

e

r

is

a

nt

r

o

e

th

e

15 - 15 Nm

o

u

r

a

a

s

c

s

c

le

e

p

n

t

16 - Mechanical distribution frontu

cover

a

n

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e

d

y

i

17 - Water pump

l

r m

i

a

e

b

i

p

l

page 79 .

i

t

y

Remove and install t

w

s

n

o

i

18 - Pulley

t

h

i

r

,

e

e

s

l

p

o

19 - Crankshaft gear

h

e

w

c

t

n

t

20 - 30 Nm

i

o

r

o

t

h

t

e

r

21 - Sleeve

a

c

p

o

n

r

i

r

22 - Fastening nut

,

e

s

c

e

t

n

s

o

e

23 - Injector pump

p

s

r

s

u

o

p

f

l

i

i

n

Remove and install page 99 .

f

c

o

r

e

r

24 - Compact support

m

m

a

m

t

i

25 - 45 Nm

o

i

n

o

c

n

r

t

o

e

26 - 120 Nm + 90°

s

i

h

t

d

a

v

o

i

r

c

p

u

r

o

Replace after each removal.

m

f

e

g

n

n

i

t

y

.

To tighten and loosen, immobilise with the Spanner - 3415- .

C

p

o

o

C

p

y

.

r

Do not apply additional oil or greaset

on the thread and flange.

i

h

g

g

h

i

t

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14 Rep. Gr.13 - Crankshaft, pistons

A

n

P

.G

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

Tightening continuation can be carried out in various steps.

27 - 40 Nm + 90°

agenA

o

nAGd

.V

lkswa

ge

w

G

o

e

s

s

n

Replace after each removal.

b

lk

o

V

ot

d

y

e

is

28 - Mechanical distribution lower cover

r

o

th

u

a

29 - Protector

le

s

s

30 - 10 Nm

d

u

n

tte

m

i

r

p

e

t

o

n

the toothed belt semi-automatic tensioning

Installation positioniofs

pulley

,

l

e

o

h

w

– The fasteningidevice -arrow- of the tensioning pulley must fit

n

into the slot ofothe mechanical distribution rear cover.

r

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

1.1

r

- remove and install

Poly-V beltv

o

e

t

a

i

r

Special tools and workshop equipment required

p

r

o

f

g

♦ Pin -T 10060-

n

o

i

y

p

C

.

t

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g

i

r

y

p

o

c

k

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b

d

e

s

w

a

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et

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or

e

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guarant ee

or a c c e p t a

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l i a

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w

									n	i	n
								t
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t

1.1.1Remove the Poly-V belt

Note

♦Mark the rotation direction before removing the Poly-V belt.

♦When installing the belt, pay attention to the correct seating on the pulleys.

1. Engine - disassemble and assemble 15

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

–Remove the lower noise insulation from the engine.

–Mark the Poly-V belt rotation direction.

1.1.2Vehicles without air conditioning com pressor

–By using a fixed wrench, turn the tensioning device clockwise -arrow- to loosen the Poly-V belt.

–Lock the tensioning device with the Pin -T 10060 - .

–Remove the Poly-V belt.

1.1.3Vehicles with air conditioning compres sor

– By using a star wrench, turn the tensioning device clockwise

-arrow- to loosen the Poly-V belt.

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- .

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b

– Lock the tensioning device with the Pin -T 10060d

e

is

– Remove the Poly-V belt.

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

1.1.4

i

-V belt.

r

o

t

Install the Polyr

a

p

n

i

– Install in reverse order from the removal.

,

s

e

s

Note

o

p

r

u

p

l

a

i

c

r

e

♦ Before installing the Poly-V belt, make sure all assemblies

m

( Generator (Alternator) -C-m,air conditioning compressor, in

o

c

jector pump) are properly installed.

r

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♦ When installing the Poly-V belt,apay attention to the operation

v

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direction and correct seating of the belt in the respective pul

leys.

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16 Rep. Gr.13 - Crankshaft, pistons

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Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

– StarttheengineandcheckthecorrecttravelofthePoly-Vbelt.

1.2Toothed belt semi-automatic tensioning pulley - check

1.2.1Checking conditions

•Toothed belt installed and adjusted.

1.2.2Checking sequence

–Press the toothed belt -seta- firmly with the thumb. Notch and elevation -arrow- must be displaced.

–Release the toothed belt. The tensioning pulley must return to its initial position. (Notch and elevation are juxtaposed again).

–If the notch and the elevation are not juxtaposed, loosen the tensioning pulley and adjust the toothed belt tension

page 36 .

–If the toothed belt tension is changed:

–Checktheinjectionstartdynamically,andoccasionally,adjust functions and components page 108 .

.

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.G 1. Engine - disassemble and assemble

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4 - Cyl. diesel engine - Edition 08.2010

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seal - re

Crankshaft and flywheels

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move and install

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Clutch repair work: Automatic /omechanical transmission; Rep.

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Gr. 30 ;Clutch - command systemw .

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WARNING

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Alwaysreplaceself-lockingnutso andscrewssubjecttoangular

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1 - Crankshaft seal (pulley

m

m

side)

Do not lubricate or grease on the seal lip.

Before installation, re move oil residues from crankshaft trunnion with clean cloth.

Replace the crankshaft seal (pulley side)

page 20 .

2 - Crankshaft flange (pulley side)

It must seat on coupling guides.

Remove and installpage 23 .

Install with Engine sili cone seal -D176 404 A2 or A3- page 23 .

3 - Engine block

Crankshaft - remove and install page 26 .

Piston and connecting rod - remove and installpage 28 .

4 - 60 Nm + 90°

Replace after each re moval.

The angular torque can be applied in several stages.

5 - Steering wheel

Forremovingandinstal

ling, use the Flywheel lock -T 10044and Sleeve -T 10044/1- page 19

6 - Intermediate plate

It must seat on coupling guides.

Do not damage or bend during installation.

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18 Rep. Gr.13 - Crankshaft, pistons

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

7 - 15 Nm

8 - Crankshaft flange (flywheel side) with seal

Replace as a set only.

Do not lubricate or grease on the seal lip.

Before installation, remove oil residues from crankshaft trunnion with clean cloth.

To install, use the coupling guide supplied by the manufacturer.

The coupling guide can only be removed after installing the seal on the crankshaft trunnion.

9 - 15 Nm

Flywheel - remove and install

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equipment required

Special tools and workshopi

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♦ Flywheel lock -Ta10044- -T10044- with Sleeve -T10044/1-

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Fasten the Flywheel lock -T 10044with a Sleeve -T10044/1- to

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remove and install thes engine flywheel.

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2. Crankshaft and flywheel seal - remove and install 19

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

2.1Crankshaft sealing (pulley side) - replace

Special tools and workshop equipment required

♦Puller -3203-

♦Wrench -3415-

♦Assembly sleeve -T 10053-

♦Torque wrench - 5 to 50Nm (enc. 1/2") -VAG 1331-

♦Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-

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2.1.1	Removal	u
		p
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		m
– Remove the left front wheel case cover Body - External
		m
		o
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assembly works; Rep. Gr. 66 ; External equipment .
		r
		o
		t
– Remove the Poly-V belt pagea15 .
		v
		i
		r
		p
		r
– Remove the toothed belt page 36 .
		o
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– Remove the toothed belt . To do that,pimmobilise the crank
shaft gear with the Wrench -3415- .				o
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20 Rep. Gr.13 - Crankshaft, pistons

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Fox 2004

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4c- Cyl. diesel engine - Edition 08.2010

s

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p

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a

– To guidee d

the Puller -3203- , install the central screw manually

n

y

t

l

i

t

i

a

onmthe crankshaft to the limit.

b

p

e

r

the inside part of the external part of the Puller -3203-

t

– Turno

n

isnine turns (approx. 20 mm) and immobilise it with the knurled

,

e

l screw.

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–r Lubricate the threaded head of Puller -3203- , place and turn

e

mit with strong pressure on the seal.

m

o

c

r

– Loosen the knurled screw and turn the inner part of the Puller

o

- against the crankshaft until extracting the seal.

-3203e

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2.1.2Installation

Note

Gradual introduction of PTFE seals (Feature: springless, wider seal lip).It is prohibited to lubricate the seal's sealing lip.An old modelofsealwithradialgrooves(springless)maybereplacedby a PTFE seal, but the inverse replacement is not permitted.

–With a clean cloth, remove oil residues from the crankshaft trunnion.

–Place the Sleeve -T10053/1- onto the crankshaft trunnion.

–Slide the seal over the Sleeve -T10053/1- , in the crankshaft trunnion, and remove the Sleeve -T10053/1- .

2. Crankshaft and flywheel seal - remove and install 21

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

–Install the seal with the Assembly sleeve -T 10053and screw -T10053/2- ( Left turning light bulb -M18- x 1.5 x 60), pressing it to the stop.

–Install the crankshaft gear and immobilise with the Spanner -3415- . Tightening torque: 120 Nm + 90°.

Note

The thread and the screw head support face must be free from oil and grease.

Installing the toothed belt and adjusting distribution times

page 36 .

– Install Poly-V belt page 15 .

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22 Rep. Gr.13 - Crankshaft, pistons

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

2.2Crankshaft flange (pulley side) - remove and install

Special tools and workshop equipment required

♦Puller -3203-

♦Wrench -3415-

♦Assembly sleeve -T 10053-

♦Torque wrench - 5 to 50Nm (enc. 1/2") -VAG 1331-

♦Torque wrench - 40 to 200Nm (enc. 1/2") -VAG 1332-

y

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2.2.1

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Removal

n

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the Poly-V belt page 15 .

a

– Removep

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– Remove the toothed belt page 36 .

s

o

p

– Remover the crankshaft gear. To do so, immobilise the gear

u

p

l

using the Wrench -3415- .

a

i

c

r

e

– Drain the engine oil.

m

m

o

– Remove the crankcase page 65 .

c

r

o

e

t

– Loosen the front flange.

a

v

i

r

p

r

– Removethefrontflange,ifnecessary,bylooseningitwithlight

o

f

g

knocks with a rubber hammer.

n

i

y

p

o

– Eliminate residues ofCEngine silicone seal -D176 404 A2 or

.

t

i

h

g

A3remaining on the enginegir

block with a spatula.

h

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2. Crankshaft and flywheel seal - remove and install 23

Fox 2004

4 - Cyl. diesel engine - Edition 08.2010

–Remove residues of Engine silicone seal -D176 404 A2 or A3with the plastic brush installed in drill (use goggles).

–Clean the sealing surfaces. They must be free from oil and grease.

2.2.2Installation

Note

♦Observe the expiration date of the Engine silicone seal -D176 404 A2 or A3- .

♦After applying the Engine silicone seal -D176 404 A2 or A3- , the flange must be installed within 5 minutes.

–Cut the tube injector on front marking (ejector Ø is approx. 3 mm).

Note

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♦ The Engine silicone seal -D176 404VA2 or A3-fillet should not

s

s

n

lk

o

bethicker;otherwise,theexcesseofEnginesiliconeseal-D176

y

b

404 A2 or A3may fall into thet

d

crankcase, where it may clog

is

r

o

h

tube.

the screen filter in the suctionsa

u

s

le

silicone seal -D176 404 A2 or A3-

♦ Before applying the Engineu

n

d

with a clean cloth.

fillet, cover the seal surfaceitt

m

e

p

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t

o

seal -D176 404 A2 or A3fillet on the

– Apply Engine silicones

n

surface, as shown in the illustration.

clean flange seall

i

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e

o

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the flange and tighten the screws lightly.

– Immediately positionw

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24 Rep. Gr.13 - Crankshaft, pistons

Fox 2004 4 - Cyl. diesel engine - Edition 08.2010

Note

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es

To place the flange with installed seal,lksuse the Sleeve -

d

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T10053/1- .

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is

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screws in a cross pattern. Tight

– Tighten the flange fastenings

u

ening torque: 15 Nm.l

a

s

n

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d

u

page 65 .

– Install crankcaseitt

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p

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r

m

t

o

Note

n

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i

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e

l

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the Engine silicone seal -D176 404 A2 or A3-

After installation,w

h

must dry for 30r minutes.Motor oil may be replenished only after

n

i

this time period has elapsed.

o

t

r

a

p

n

i

– Install the crankshaft gear and immobilise with the Spanner

,

s

e

torque: 120 Nm + 90°.

-3415- . Tighteningp

s

o

r

u

p

l

Note

a

e

i

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r

m

m

The thread and the screw head support area must be free from

o

oil and grease.

c

e

r

o

t

a

v

i

r

Installing the toothed beltf and adjusting distribution times

p

r

page 36 .

o

i

g

n

y

p

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– Install Poly-V belt page.t15 .

C

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2. Crankshaft and flywheel seal - remove and install 25

Fox 2004

lksw

en

4 - Cyl. diesel engine - Edition 08.2010

g

a

o

V

y

b

d

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is

3

r

Crankshaft - remove and installs

o

th

u

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le

d

u

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WARNING

itt

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r

Alwaysreplaceself-lockingnutsandscrewsosubjecttoangular

t

torque

is

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l

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i

1 - Bearing shells 1, 2, 3, 4 and

r

5

For bearing cover with out lubrication groove.

For crankcase with oil groove.

Do not mix the bearing shells when reusing them (mark them)

2 - 65 Nm + 90°

Replace after each re moval.

To measure the radial clearance, tighten to 65 Nm, without angular tor que.

3 - Bearing cap

Bearing cap 1: Crank shaft pulley side:

Bearing cap 3: With notches for adjusting rings.

The shoulders for plac ing the bearing shells, crankcase/bearing cap must be overlapped.

4 - Bearing 3 shell bearing

For bearing cover with out lubrication groove.

For engine block, with lubrication groove.

5 - Adjustment rings

For bearing 3 cover.

Check fastening.

6 - Rotor

To Engine speed sensor - G28-

7 - 10 Nm + 90°

Replace after each removal.

8 - Adjustment pin

Check crankshaft salience page 15

9 - Crankshaft

AG.

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										i
										n
										f
										o
										r
										m
										a
										t
										i
							n	i	n	o
						t
			d	s	i	h
		o
	c

New axial clearance: 0.07...00.17 mm. Wear limit: 0.37 mm.

Measure radial clearance with “Plastigage”: new: 0.03...00.08 mm. Wear limit: 0.17 mm.

Do not rotate crankshaft while measuring radial clearance.

Crankshaft measures page 26 .

26 Rep. Gr.13 - Crankshaft, pistons