Volkswagen FOX 2004 Instruction manual

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

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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Cylinders, engine block, support, cover
13 - Crankshaft, pistons
15 - Cylinder head, valve control mechanism
17 - Lubrication system
19 - Cooling system
20 - Supply system - Fuel tank, fuel pump
21 - Overcharge - turbo
23 - Supply system - mechanical injection (diesel)
26 - Exhaust system
28 - Chamber pre-heating system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg BRA5R007720

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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Cylinders, engine block, support, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Engine - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removal - indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Engine - fix on assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Notes regarding installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Supports for the power drive group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Additional removal information and instructions for vehicles with air conditioning . . . . . . . . 8
13 - Crankshaft, pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Engine - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Crankshaft flanges and flywheel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Crankshaft oil seal, pulley side - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Crankshaft seal flange - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Counterbalance shaft and retaining frame - remove and install . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Counterbalance shaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Crankshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Pistons and connecting rods - dismantle and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
15 - Cylinder head, valve control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Timing belt - remove and install, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Compression - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Valve command - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Valve seats - rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Valve guides - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Valve stem seal - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.4 Camshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
17 - Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 Lubrication system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.1 Crankcase - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 Checking the oil pressure and the oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Cooling system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 Cooling system components in the body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Cooling system components in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Cooling system hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Cooling system - drain and replenish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.5 Radiator - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.6 Water pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.7 Thermostat - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
Contents i

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20 - Supply system - Fuel tank, fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1 Fuel supply system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.1 Fuel tank components with accessories - remove and install . . . . . . . . . . . . . . . . . . . . . . 84
1.2 Fuel filter - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.3 Safety measures for working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Fuel tank - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.6 Fuel pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.7 Fuel meter sensor - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.8 Fuel pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.9 Accelerator mechanism - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.10 Auxiliary pump - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.11 Auxiliary pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
21 - Overcharge - turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1 Overcharge system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.2 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.3 Turbocharger - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.4 Intake air cooling system (intercooler) components - remove and install . . . . . . . . . . . . . . 104
23 - Supply system - mechanical injection (diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1 Maintaining the direct injection Diesel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Installation locations - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3 Cleanliness rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.4 Intake manifold valve - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Injectors - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.6 Sealing ring for injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.7 Injectors - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Engine command unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Engine command unit - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Querying and erasing fault memory of the engine command unit . . . . . . . . . . . . . . . . . . . . 115
2.3 Adjusting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1 Exhaust system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.1 Exhaust gas recirculation system components - remove and install . . . . . . . . . . . . . . . . . . 120
2.2 Vacuum hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
28 - Chamber pre-heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1 Chamber pre-heating system - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Checking heating plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
ii Contents

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00 – Technical data
1 Technical data
1.1 Engine number
Engine number (“identification letters” and “serial number”) is en‐
graved on the flange between the engine and the transmission.
The engine number comprises a maximum nine digits (alphanu‐
merical). The first part (max. of three identification letters) repre‐
sents the “the engine ID letters”; the second part (six characters)
represents the “serial number”. If more than 999,999 engines are
manufactured under the same identification letters, the first digit
of the 6-digit group is replaced by a letter.
Additionally a sticker is found on the upper cover of the mechan‐
ical distribution system -arrow- with the “engine identification
letters” and the “serial number”.
The “engine identification letters” are also indicated on the vehicle
data plate.
1.2 Engine features
Engine codes BNM
Production 11.04 ▸
Cylinder volume l 1,4
Power kW / rpm 51/4000
Torque Nm / rpm 155/1600 to 2800
Bore ∅Ø mm 79,5
Stroke mm 95,5
Compression rate 19,5
Octanage at least 49
Firing order 1-2-3
Catalytic converter yes
Recirculation of exhaust gases yes
Charged yes
Intercooler yes
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Technical data 1

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10 – Cylinders, engine block, support, cover
1 Engine - remove and install
Special tools and workshop
equipment required
♦ Lifting tackle -2024A-
♦ Engine and gearbox sup‐
port -T10012-
♦ Engine and gearbox sup‐
port -VW 313-
♦ Engine and gearbox sup‐
port -VW 540-
♦ Workshop winch -
V.A.G 1202 A-
♦ Oil sump -V.A.G 1306-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
2 Rep. Gr.10 - Cylinders, engine block, support, cover

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♦ Torque wrench - 5 to 50 Nm
( enc. 1/2") -VAG 1331-
♦ Torque wrench - 40 to 200
Nm ( enc. 1/2") -VAG 1332-
♦ Jack for Gearbox or engine
+ gearbox combo -VAG
1383A-
♦ Standart-type clamp pliers -
VAS 5024A-
♦ Stepladder -VAS 5085-
♦ Engine and gearbox sup‐
port -3147-
♦ 3 Washers A13 X 24 X 2.5
♦ 2 Washers A10.5 X 21 X 2
♦ Cable tie
♦ Support bracket -10-222A- with Rack -10-222A/1-
♦ Adapter -10-222A/18-
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 3

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.
Modifying Engine bracket -T10012-
– If the modification has not yet been carried out, drill an addi‐
tional hole -a- to the prescribed dimensions at the same height
as the other holes.
1.1 Removal - indications
Note
Check whether vehicle has code radio, if so obtain the anti-theft
code before disconnecting earth lead from battery.
– The engine is removed downwards, along with transmission.
WARNING
For installation jobs, especially in the engine compartment, due
to reduced existing space, consider the following:
♦ All hoses (fuel, hydraulics, activated charcoal filter sys‐
tem, cooling fluid and gas, brake fluid, vacuum) and elec‐
tric cables must be restored to original positions.
♦ Provide easy access to all the moving or hot parts.
– With ignition switched off, disconnect battery earth lead.
– All cable ties that open or break during engine removal should
be replaced and installed at the same locations when engine
is installed.
– Release the supply and return hoses in the cylinder head.
WARNING
♦ The fuel and the fuel system hoses may be very hot (burn
risk)!
♦ Fuel system is under pressure!
♦ Use protective gloves and goggles when performing any
repairs on the fuel system!
– Remove connecting pipe between intercooler and intake con‐
necting flange.
– Remove air mass meter hose from turbocharger.
– Remove lower noise insulation from engine ⇒ Rep. Gr. 50
– Remove intercooler/turbocharger hose.
– Remove Poly-V belt ⇒ page 14 .
– Drain the cooling system ⇒ page 76 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
4 Rep. Gr.10 - Cylinders, engine block, support, cover

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– Release the radiator cooling system hoses from the engine by
using Hose clamp pliers -V.A.G 1921- or Standart-type clamp
pliers -VAS 5024A- .
– Remove/disconnect all the electric connections from the en‐
gine where necessary.
– Remove all the cooling, vacuum and intake system hoses from
the engine.
– Remove securing bolt of the cable support bracket and secure
clutch release lever by inserting a Locking pin -T10060 A-
-arrow-.
– Remove securing bolts from the top of engine/gearbox.
– Remove cooling fluid container.
– Unbolt starter motor and move it back until the Support -3147-
can be inserted.
– Install the Support bracket -10-222A- and support engine and
gearbox as shown in diagram.
– Remove engine support -1- and engine console -2-.
– Disconnect right-hand drive shaft⇒ Rep. Gr. 40 .
– Loosen front exhaust pipe from turbocharger. Loosen double
clamp and push exhaust pipe backwards ⇒ page 118 .
– Remove the protection plate behind the drive shaft flange.
Vehicles with air conditioning:
– For removal, refer to the additional information and instruc‐
tions ⇒ page 8 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 5

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– Install support pin to the engine bracket-1- with one washer
and the pin -2- with two A13 X 24 X 2.5 washers as shown in
the illustration -arrows-.
– Then, secure the Engine bracket -T10012- with nut -3- and
securing bolt from the compact bracket on the engine block.
Note
Place two A 10.5 X 21 X 2 Washers between engine bracket and
compact bracket so that the engine bracket lies flat on the com‐
pact bracket.
– Remove securing bolts from the bottom of engine/gearbox.
– Lift engine and gearbox lightly using the Gearbox or Engine +
gearbox combo jack -VAG 1383A-
– Remove the spindle of the Support bracket -10-222A- on the
engine side.
Note
Use Stepladder -VAS 5058- to remove the spindle.
– Separate engine from gearbox by carefully lowering it and us‐
ing the Gearbox or Engine + gearbox combo jack -VAG
1383A;- remove it from below.
Note
When lowering, handle the engine carefully to prevent damaging
the body.
1.2 Engine - fix on assembly stand
To perform the assembly work, the Engine and gearbox support
-VW 540- must be fastened on the assembly stand -VW 313- .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
6 Rep. Gr.10 - Cylinders, engine block, support, cover

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Work sequence
– Attach with Lifting tackle -2024A- as follows and lift a little with
the Engine/gearbox combo jack -VAG 1383A- .
Pulley side: 4th hole of the bar in position 1.
Engine flywheel side: 2nd hole of the bar in position 8.
WARNING
On hooks and pins, use safety locks -arrows-.
Note
♦ Positions numbered 1...4 on suspension bar face toward the
pulley.
♦ Drilled holes on supports are counted from the hook.
– Fasten the engine with the Support -VW 540- on the Stand -
VW 313- .
1.3 Notes regarding installation
Installation is carried out by reversing the removal sequence,
considering the following:
– Check clutch bearing for wear, replace if necessary.
– Apply a light coat of Lubricating grease -G 000 100 - on the
clutch bearing and on the primary shaft bearing guide sleeve.
– Check if guides for fastening engine and transmission are
placed on the engine block and, if necessary, install them.
– Align engine, moving it slightly so that the supports are seated
without stress.
Note
Assembly support tightening torques ⇒ page 8 .
– Electrical conections and installation ⇒ Rep. Gr. 97 :
– Remove Locking pin -T10060- -arrow- and replace securing
bolt.
– Install drive shaft ⇒ Rep. Gr. 40 .
– Install the front exhaust pipe ⇒ page 118 .
– Install Poly-V belt ⇒ page 14 .
– Install air filter/turbocharger, intercooler/turbocharger and in‐
tercooler/intake flange hoses.
– Fill cooling system ⇒ page 76 .
– Install engine noise insulation ⇒ Rep. Gr. 50 .
– Perform test drive and check fault memory ⇒ page 115 .
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - remove and install 7

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1.4 Tightening torque
Location Tightening tor‐
que
Screws, nuts M 6 10 Nm
M 8 20 Nm
M 10 45 Nm
M 12 60 Nm
Different tightening torques
Front exhaust and turbocharger pipe 25 Nm
1.5 Supports for the power drive group
Tightening torque
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Power drive group suport, engine
1 - 1) = 30 Nm + 90°.
2 - 1) = 40 Nm + 90°.
3 - 45 Nm.
1) Replace.
1.6 Additional removal information and in‐
structions for vehicles with air condition‐
ing
Note
♦ The air conditioning cooling gas circuit must be opened in or‐
der to remove the engine.
♦ To prevent damages to condenser and cooling gas hoses, do
not fold, twist or overstretch the hoses.
– Remove air conditioning compressor and anchor it to the body.
⇒ Rep. Gr. 87 .
– Purge the cooling gas from air conditioning circuit and open
the gas circuit ⇒ Rep. Gr. 87 .
Note
The air conditioning compressor may remain fitted in its place.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
8 Rep. Gr.10 - Cylinders, engine block, support, cover

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13 – Crankshaft, pistons
1 Engine - dismantle and assemble
Note
♦ Where large quantities of metal shavings and filings are de‐
tected in the engine oil during repair required as a result of
crankshaft and connecting rod bearing wear, the oil filter must
be replaced and the oil channels carefully cleaned.
♦ All bearing and running surfaces must be lubricated before
assembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 9

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I ⇒ page 10
II ⇒ page 11
III ⇒ page 12
Part I
1 - Timing belt guard - upper
part
2 - Timing belt
❑ Mark rotation direction
before removal.
❑ Check wear.
❑ Do not bend.
❑ Remove, install, and ad‐
just ⇒ page 41 .
3 - 20 Nm +45°
❑ Replace after each
remova.l
4 - Timing belt tension pulley
5 - 100 Nm
6 - 25 Nm
7 - Camshaft gear
8 - Pulley
❑ Engine speed sensor.
❑ Immobilise with Coun‐
ter-hold tool -T10051- to
loosen or tighten.
❑ To remove, use Extrac‐
tor -T10052- .
❑ Remove and install
⇒ page 58 .
9 - 10 Nm
10 - Mechanical distribution
rear cover
11 - Sealing ring
❑ Replace if damaged.
12 - Pulley
13 - Water pump
❑ Remove and install ⇒ page 80 .
14 - Crankshaft gear
15 - 120 Nm + 90°
❑ Replace after each removal..
❑ Immobilise with Lock -3415- to loosen or tighten.
❑ Do not apply additional oil or grease to the threads and recess/flanges.
❑ The angular torque can be performed in several stages.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
10 Rep. Gr.13 - Crankshaft, pistons

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16 - 15 Nm
17 - 20 Nm
18 - Lower part of mechanical distribution cover
19 - Vibration cushioning pulley
❑ It can be installed in one position only. The holes are displaced.
20 - 10 Nm + 90°
❑ Replace after each removal.
21 - Timing belt guard - centre part
Part II
1 - Cylinder head cover
❑ With oil filler nozzle.
❑ Replace oil filling nozzle
if cylinder head cover is
damaged.
❑ Before installation,
carefully clean the cylin‐
der head sealing sur‐
face with a clean cloth.
2 - To turbocharger
3 - 10 Nm
❑ First, hand tighten all
bolts.
❑ Then, tighten both top
and remaining bolts
from the inside out, di‐
agonally, to specified
tightening torque.
4 - Pressure regulating valve
❑ To crankcase vent.
5 - Cover
❑ Replace seal if dam‐
aged.
6 - Gasket
❑ Replace if damaged.
7 - Oil filling nozzle
❑ Replace.
8 - Engine and gearbox sup‐
port
❑ With fuel tube.
9 - Cylinder head cover gasket
❑ Replace if damaged.
10 - 20 Nm
11 - Lifting eye
12 - 10 Nm
13 - Central connector
❑ To injector
14 - From servo brake
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 11

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15 - Tandem pump
❑ For supplying fuel and vacuum.
❑ Remove and install ⇒ page 97 .
❑ Check ⇒ page 95 .
16 - 25 Nm
17 - Supply hose
❑ From fuel filter ⇒ Item 1 (page 87) .
❑ White or with white marking.
❑ Check that it is securely installed.
❑ Fasten with spring braces.
18 - Return hose
❑ To fuel filter ⇒ Item 1 (page 87) .
❑ Blue or blue marked.
❑ Check that it is securely installed.
❑ Fasten with spring braces.
19 - Gasket
❑ Replace.
20 - Pin 10 Nm
❑ To engine cover.
21 - Engine and gearbox support
22 - Hexagonal nut
23 - Cylinder head gasket
❑ Replace.
❑ Observe identification ⇒ page 35 .
❑ When replacing, use completely new coolant.
24 - Hall Sensor -G40-
❑ To the camshaft position.
❑ Loosen to remove sealing ring from the mechanical distribution rear cover.
25 - Cylinder head securing bolt
❑ Replace.
❑ Follow the installation and removal sequence ⇒ page 46 .
❑ Insert washers into cylinder head before installing.
26 - Injectors
❑ Remove and install ⇒ page 112 .
Part III
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
12 Rep. Gr.13 - Crankshaft, pistons

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1 - 45 Nm
2 - Engine bracket
3 - Engine block
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 17 .
❑ Disassemble and as‐
semble pistons and con‐
necting rods
⇒ page 32
4 - Connection, 40 Nm
❑ To turbocharger oil re‐
turn pipe .
❑ Replace.
5 - Spacer sleeve
6 - Rubber bushing
7 - Engine and gearbox sup‐
port
❑ To the Sensor Hall -
G40- connector of the
camshaft position and
Engine speed sensor -
G28- .
8 - 10 Nm
9 - Gasket
❑ Replace.
10 - Oil filter bracket
❑ Disassemble and as‐
semble ⇒ page 64 .
11 - 15 Nm + 90°
❑ Replace after each re‐
moval.
❑ First, install upper left and lower right bolts, then tighten the four bolts diagonally.
12 - Sealing ring
❑ Replace.
13 - 20 Nm
14 - Engine speed sensor -G28-
15 - Connection
❑ To temperature sensor.
16 - 15 Nm
17 - Coolant temperature sensor
❑ Remove and install ⇒ page 82 .
18 - 45 Nm
❑ Torque sequence: from inside out.
19 - Compact bracket
❑ To alternator, air conditioning compressor and Poly-V belt tensioning element.
❑ See the locating guide between compact bracket and engine block.
20 - Tensioning element
❑ To Poly-V belt.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 13

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21 - 25 Nm
22 - Oil crankcase
❑ Clean sealing surface before installation.
❑ Install with Silicone sealant -D 176 404 A2 - ⇒ page 68
❑ To remove crankcase, first remove the transmission ⇒ Rep. Gr. 34 .
23 - 15 Nm
❑ To remove the rear bolts close to the transmission, it first must be removed⇒ Rep. Gr. 34 .
24 - Cover
❑ With sealing tape.
❑ Clean filter if dirty.
25 - Mounting frame
❑ Before installing, check whether the fixing guides for centralizing on the engine block are in their place,
and that the fuel distribution ring is inserted in the mounting frame.
❑ Remove and install ⇒ page 23 .
26 - 40 Nm
27 - Protective cover
❑ To drive shaft.
1.1 Poly-V belt - remove and install
Special tools and workshop equipment required
♦ Retaining pin -T10060 A-
♦ Spanner 15 mm AF
1.1.1 Removal
– Remove lower noise insulation from engine ⇒ Rep. Gr. 50 .
– Remove the hose between intercooler/intake flange and the
air mass meter.
– Mark Poly-V belt rotation direction.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
14 Rep. Gr.13 - Crankshaft, pistons

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– Turn tensioning element in arrow direction to relieve tension
on Poly-V belt.
– Lock tensioning element with Retaining pin -T10060A- .
– Remove Poly-V belt.
1.1.2 Installation
– The installation is carried out by inverting the removal se‐
quence.
Note
♦ Make sure before installing Poly-V belt that all the ancillaries
(alternator, air conditioning compressor) are tightlysecured .
♦ When fitting Poly-V belt, observe the direction in which it func‐
tions and check it is seated correctly on the pulley.
♦ In vehicles without air conditioning, installation of Poly-V belt
on the alternador must be the last step.
♦ In vehicles with air conditioning, installation of Poly-V belt last
on the air conditioning compressor.
When the job is finished, always:
– Start the engine and check belt movement.
Belt path for vehicles without air conditioning.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
1. Engine - dismantle and assemble 15

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Belt path for vehicles with air conditioning.
Fox 2004 ➤
3 - Cyl. diesel engine - Edition 02.2009
16 Rep. Gr.13 - Crankshaft, pistons