VOLKSWAGEN FOX 2004 (02) PDF Document

The engine features for the VOLKSWAGEN FOX 2004 are as follows:

When working on the fuel system of the VOLKSWAGEN FOX 2004, observe the following safety measures:

The 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 to catch escaping fuel. Eliminate pressure by pulling the tube carefully.

Before starting installation works, place a suction hose for extracting equipment near the fuel reservoir opening to absorb gases released by the fuel. If extracting equipment is unavailable, use a radial fan (keep the engine out of the air flow) with an air movement rate higher than 15 cubic meters per hour.

For safety reasons, before opening the fuel system, remove fuse number 33 from the fuse holder, as the fuel pump (pre-supply pump) G6 can be activated.

Always replace fastening clamps with spring clamps. Using tightening clamps and bolted clamps is not allowed for fuel tubes in the engine compartment.

To check the compression of the VOLKSWAGEN FOX 2004, ensure the engine oil temperature is at least 30 degrees Celsius. Follow these steps:

Step 1. Disengage the 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.

Step 2. Remove all ignition coils with the puller T10094.

Step 3. Remove the spark plugs Q with spark plug wrench 3122B.

Step 4. Remove fuse 44 to disable the injection valves.

Step 5. Check compression using the cylinder compression meter for gasoline/alcohol VAG 1763. Operate the starting motor until the testing device does not indicate any further increase in pressure.

The compression values are as follows: Cylinder compression: 10.0 to 15.0 bar; Wear limit: 7.0 bar; Maximum compression difference between cylinders: 3.00 bar.

Step 6. Install the spark plugs Q with spark plug wrench 3122B and tighten to 30 Nm.

The coolant mixture for the VOLKSWAGEN FOX 2004 must be prepared using G 12 coolant additive. Do not reduce coolant concentration by adding water. The percentage must be at least 40%. The recommended mixture proportions are:

The coolant volume may vary according to the equipment on each vehicle.

To check the oil pressure on the VOLKSWAGEN FOX 2004, ensure the oil level is correct and the engine oil temperature is at least 176 degrees Fahrenheit (the radiator fan V7 must have been activated at least once).

Step 1. Remove the oil pressure switch F1 and install the oil pressure meter VAG 1342 in its place on the engine head.

Step 2. Put the tester brown cable on the earth (-).

Step 3. Connect the voltage control V.A.G 1527 B with auxiliary cable V.A.G 1594 A to the battery positive terminal (+) and the oil pressure switch F1. The LED shall not light up.

Step 4. Run the engine and slowly increase the rpm. At a 0.3 to 0.6 bar positive pressure, the LED should light up. If not, replace the oil pressure switch F1.

Step 5. Continue to increase the engine speed. At 2000 rpm and an oil temperature of 80 degrees Celsius, the oil pressure should be at least 2.0 bar. At higher speeds, positive oil pressure may not exceed 7.0 bar.

Removal:

Step 1. Pull off the intake air duct.

Step 2. Loosen the spring clamp with the VAS 5024A or equivalent clamp pliers and pull the air duct from the upper part of the air filter set.

Step 3. Remove the left bolt fastening the air filter set.

Step 4. Tilt the battery cover forwards.

Step 5. Move the air filter set upwards and remove it.

Installation:

Step 1. Seat the air filter set on the rubber supports.

Step 2. Press the air filter set downwards onto the pins.

Step 3. Tighten the fastening bolts to 8 Nm.

Step 4. Fasten the air duct with the spring clamp on the upper part of the air filter set.

Step 5. Install the intake air duct on the intake nozzle.

To check the injection valve flow and tightness on the VOLKSWAGEN FOX 2004, ensure the fuel pressure and residual pressure are within specifications.

Step 1. Remove the 2-pole connector from the cooling system temperature sensor G62 and connect the digital potentiometer (VAG 1630) to the 1 and 2 contacts, adjusting the resistance to 15 kOhm.

Step 2. Remove the supply hose from the fuel distributor and install it over the oil separator hose.

Step 3. Remove the injection valve harness from the fuel distributor bearings and remove the bolts fastening the fuel distributor.

Step 4. Disengage the ignition coil connectors.

Step 5. With the fuel distributor removed from the cylinder head, keep a container below the injection valves. Have someone operate the starter motor. Fuel loss must not exceed 2 drops a minute. If it is greater, turn the ignition off and replace the damaged injection valve.

To check flow, connect one injection valve contact to the motor earth and the other to the battery positive terminal using the remote control VAG 1348A. Place the injection valve in a graduated container. Activate the remote control for 30 seconds. The nominal value is 85 to 91 ml per valve. If values are outside this range, replace the damaged injection valve.