VOLKSWAGEN FOX 2004 (05) PDF Document

Ensure the engine oil temperature is at least 30°C and the battery voltage is at least 11.5 volts. Turn off all electrical components and air conditioning. Remove the air filter body, the spark plugs using spark plug wrench 3122B, the hall sensor 3-pole connector, and the ignition transformer 4-pole connector. Remove fuse 44 to stop the fuel supply to the injectors. Have another person hold the accelerator pedal down completely to open the butterfly valve. Use a cylinder compression meter to measure and operate the starter until the pressure stops increasing.

For vehicles with air conditioning, remove the lower noise insulation and mark the rotation direction of the belt. Turn the belt tensioning element in the arrow direction using a 16-mm spanner to loosen it, then remove the belt. For installation, place the belt on the crankshaft pulley first, then on the tensioning element in reverse order. After installation, always start the engine and check the belt movement.

Remove the lower noise insulation, heat baffle, and front exhaust tube. Remove the clutch compartment cover and drain the engine oil. Remove the four internal fastening bolts on the pulley side of the oil crankcase and loosen the remaining bolts. Carefully remove the crankcase, tapping it with a rubber hammer if necessary. Clean all sealing residues from the engine block using a flat spatula.

Clean the sealing surfaces thoroughly, ensuring they are free of oil and grease. Apply silicone sealant (D 176 404 A2/A3) to the clean sealing surface of the crankcase. The sealing cord must be 2 to 3 mm thick and run on the inside of the bolt hole region. Install the crankcase immediately and tighten all bolts slightly, then tighten the bolts to 15 Nm. Allow the sealant to dry for approximately 30 minutes before refilling with oil.

Open the coolant reservoir cover. Remove the lower noise insulation and loosen the radiator coolant drainage plug. To replenish, ensure the cooling system is clean and use only G12 antifreeze additive. Do not mix G12 with other additives.

Before loosening any connections, place a cloth around them because the fuel system is under pressure. Remove the fuel pump (pre-supply pump) G6 with the proper spanner. Check the tightness of the joint sets from the fuel pump up to the pressure gauge. Close the cock on the pressure gauge and activate the remote control to reach approximately 3.0 bar of pressure. After 10 minutes, the pressure must not drop below 2.5 bar.

Connect the Vehicle Diagnosis, Measurement and Information System to the diagnosis connection. In the system, select “Assisted fault finding”. After querying all command units, press the skip key and select the appropriate function, such as activation, engine identification codes, systems with self-diagnosis, engine control, and then specific functions or components.

Remove the timing belt and the camshaft gear, using the special wrench 3036 to immobilize the gear. Remove the mechanical distribution rear cover. Use a puller 3240 to extract the seal by turning the inner part against the camshaft. For installation, lubricate the new seal lip with oil, install the fitting sleeves 3241, and press the seal into place using sleeve T10022/1 and fitter T10015/3. Finally, install the camshaft gear and tighten the new bolt to 20 Nm + 90°.