VOLKSWAGEN FOX 2004 (03) PDF Document

The engine is removed from below, together with the transmission. Before starting, disconnect the battery earth strap, relieve the pressure in the cooling system by opening and closing the coolant reservoir, and remove the battery and battery support. You must also remove the air filter, lower noise insulation, and front part of the exhaust tube with the catalytic converter. Drain the cooling system and disconnect all hoses, electrical connections, and the clutch hydraulic receiver cylinder before lowering the engine with the transmission using a transmission jack or engine and transmission set.

With the toothed belt installed and adjusted, press the belt firmly with your thumb. The notch and elevation on the tensioning pulley must be displaced. Release the belt; the pulley must return to its initial position, causing the notch and elevation to become juxtaposed again. If they do not align, loosen the tensioning pulley and adjust the toothed belt tension.

Ensure the oil temperature is at least 86 degrees Fahrenheit. Disengage the 10-pole connector of the injector pump and remove all pre-heating plugs. Screw the adapter into the plug sockets and connect the compression meter. Turn the starter until the meter stops indicating a pressure increase. The compression value should be between 25.0 and 31.0 bar. The wear limit is 19.0 bar, and the maximum compression difference between cylinders is 5.0 bar.

Install the injector in the injector nozzle test equipment. Press the lever downwards and read the injection pressure as the injection starts. The theoretical new injector pressure is 220 to 230 bar, with a wear limit of 190 bar. To check tightness, press the lever slowly downwards and maintain the pressure at approximately 150 bar for 10 seconds. No fuel leakage should occur at the injector opening.

Strictly observe the following six rules for the VOLKSWAGEN FOX 2004: First, clean thoroughly the connections and surrounding areas before disconnecting them. Second, place removed parts on a clean surface and cover them, ensuring you do not use cloths that fray or release lint. Third, if repair works are not to be carried out immediately, opened components must be covered or carefully preserved. Fourth, install clean components only, removing spare parts from packaging only before installation. Fifth, with the system open, avoid using compressed air if possible, and do not move the vehicle. Finally, ensure diesel fuel does not contact cooling hoses, and if it does, clean the hoses immediately as they must be changed if damaged.

Remove the oil pressure switch and install the oil pressure gauge in its place on the oil filter support. Connect the brown cable of the gauge to earth. Connect a test probe to the positive terminal of the battery and to the oil pressure switch. Start the engine and run at higher speeds; at 0.55 to 0.85 bar, the LED must light up. At 2000 rpm and an oil temperature of 176 degrees Fahrenheit, the pressure should be 2.0 bar. If these values are not reached, check for mechanical damages or replace the oil filter support.