Volkswagen Fox (2004 year). Manual — part 26
Overcharge system with turbocharg‐
er
1.1
Safety measures
WARNING
During assembly work, especially within the engine compart‐
ment, due to the lack of space, bear in mind the following :
♦ 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 original
positions.
♦ To provide easy access to all the moving or hot parts.
If during a test drive it is necessary to use test and measuring
equipment, observe the following:
♦ Always install test and measuring equipment on the back seat
to be operated by someone from there.
If test and measuring equipment are operated from the passenger
seat, the person seated there may be injured should the airbag
activate in case of accident.
1.2
Cleanliness rules
When working on the overcharge system, pay careful attention to
the following cleanliness rules :
♦ Carefully clean all the connections and surrounding areas be‐
fore disconnecting them.
♦ Place all the parts removed on clean surface and cover them.
Do not use cloth that releases lint!
♦ If repair work is not going to be carried out immediately, open
components should be covered up or carefully preserved.
♦ Install only clean components. Only remove spare parts from
packaging just prior to installing them. Do not install compo‐
nents that have been kept out of packaging (i.e. inside the tool
box, etc.).
♦ During repair services, remove oil from hose connections and
ends.
♦ With system open: If possible, avoid using compressed air. If
possible, do not move the vehicle.
1.3
Turbocharger - remove and install
Follow safety measures
⇒ page 101
.
Follow cleanliness rules
⇒ page 101
.
Fox 2004 ➤
1. Overcharge system with turbocharger
101
All the hoses are fastened with clamps or coupling fittings.
♦
When installing spring clamps, use Standart-type clamp pliers
-VAS 5024A- .
♦
Do not install hoses containing lubricant on its connections.
♦
Overcharge system must be free of leaks.
♦
Before installing the oil supply pipe, fill the turbocharger,
through the connection point, with engine oil.
♦
After installing the turbocharger, run the engine during at idle
speed for about 1 minute. Do not accelerate the engine. This
will ensure the turbocharger is properly lubricated.
♦
Always replace self-locking nuts.
Hoses with coupling connections
Note
All the overcharge system hoses are fastened with spring clamps
or connections. Always check the following points in the connec‐
tions:
– Release the connection by pulling the fixing clip -arrow-, with‐
out using tools.
– When assembling, make sure the retaining tabs -A- are firmly
secured.
Fox 2004 ➤
102
haust gases.
❑ Full replacement only.
❑ To remove, first remove
the hose between the
turbocharger/air mass
meter, intake manifold/
intercooler hose, input
flange with exhaust gas
recirculation valve, and
the intake manifold
valve motor, as well as
the drive shaft right cov‐
er.
2 - Intake manifold
3 - From the intercooler
4 - Gasket
❑ Replace.
❑ Covering (fillet) towards
the intake manifold.
5 - 25 Nm
6 - Gasket
❑ Check installation posi‐
tion.
7 - From the air filter
8 - Support
❑ From heat deflector.
9 - Washer
10 - 25 Nm
11 - Heat deflector
❑ Fasten on the bracket
12 - Hollow screw, 15 Nm
13 - Packing
❑ Replace.
14 - Hose
❑ To Electromagnetic valve for limiting charge pressure -N75- .
15 - Oil return pipe, 30 Nm
❑ To engine block.
16 - 15 Nm
17 - Gasket
❑ Replace.
18 - Front exhaust pipe
19 - 25 Nm
❑ Replace.
20 - Connection, 30 Nm
❑ Replace.
❑ Apply -G 052 112 A3- on the threads and contact surface of the screw head.
❑ Fill turbocharger with engine oil before installing the oil supply tube.
Fox 2004 ➤
1. Overcharge system with turbocharger
103
⇒ page 65
.
22 - 10 Nm
23 - Support
1.4
Intake air cooling system (intercooler)
components - remove and install
Note
♦
All the hoses are fastened by clamps.
♦
When required, use sliding agent (water without additive). Do
not use sliding agents containing oil.
♦
When repairing, remove oil from the hose connections and
ends.
♦
Overcharge system must be free of leaks.
Fox 2004 ➤
104
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