Volkswagen Fox (2004 year). Manual — part 29
– Pull the injector out of cylinder head seat with gentle taps.
1.7.2
Installation
Note
♦
After each repair, the injector requires adjustment, and the
rocker arm set screw and the injector ball head pin need to be
replaced.
♦
The new injectors are supplied with rings and heat insulation
cover.
– The heat insulation cover and rings must be replaced when
the old injector is reused
⇒ page 109
– Check whether the three rings and the heat insulation cover,
together with the fastening clip, are correctly seated before
installing the injector.
Note
The rings cannot not be twisted.
– Lubricate the rings and carefully set the injector into the cylin‐
der head.
– In a uniform manner push the injector into the cylinder head
until it stops.
– Fit the tensioning block into the slot at the injector side.
Note
If the injector is not at a right angle to the tensioning block, the
fastening screw may come loose, thus damaging the injector or
the cylinder head.
– Align the injector as follows.
– Tighten the new securing bolt into the tensioning block until
the injector can still be turned easily.
– Align the injector at a right angle to the camshaft bearing caps.
Fox 2004 ➤
1. Maintaining the direct injection Diesel system
113
(measurement range at least of 400 mm).
Cylinder
Dimension “a”
1
245.0 ± 0.8 mm
2
157.0 ± 0.8 mm
3
65.6 ± 0.8 mm
– Align the injector and tighten the securing bolt to: 12 Nm + 270°
(the angular torque could be made in several stages).
– Fit the rocker arm shaft and tighten the new securing bolts as
follows
– Tighten the inner and then both outer bolts manually and
evenly. Next, by using the same sequence, tighten to 20 Nm
+ 90°.
– Fit the Bracket -VW 387- onto the set screw as shown.
– Turn crankshaft in the engine rotation direction until rocker arm
roller is at the top of drive cam. Roller side -arrow A- positioned
at the highest point of dial gauge -arrow B- positioned at the
lowest point.
– Remove dial gauge.
– Turn set screw inwards into rocker arm until a firm resistance
is noted (injector positioned at stop).
– Turn set screw 225° back off stop.
– Hold set screw in this position and tighten the self-locking nut
to 30 Nm.
– Fit injector connector and install cylinder head cover and tim‐
ing belt guard.
Fox 2004 ➤
114
2.1
Engine command unit - remove and in‐
stall
– Before removing engine command unit, refer to the command
unit ID and this respective code
⇒ page 115
.
2.1.1
Removal
– Switch off ignition.
– Remove the windscreen wiper blades and the lower coating
of the windscreen frame.
– Release the connector on the engine command unit and pull
it off.
– Push clips -arrows- outwards and pull command unit out.
2.1.2
Installing
– Insert new command unit.
– Fit connector and lock in position.
– Check the previous code and encode the new command unit
⇒ page 116
.
2.2
Querying and erasing fault memory of
the engine command unit
Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis cable (5 m)
-VAS 5051/3-
Fox 2004 ➤
2. Engine command unit
115
– Connect Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis
cable (5 m) -VAS 5051/3- to the diagnosis connection.
– Start the engine and run it at idle speed.
Only when engine does not run:
– Switch ignition on.
Select operation mode
– Press on the
Vehicle self-diagnosis
.
Select vehicle system
– Press on the
01 Engine electronic system
.
The command unit ID and the code will be indicated on the dis‐
play.
Select diagnosis function:
– Press on the
02 Query fault memory
on the display.
– If no faults are stored in engine command unit, the display
shows “0 faults found”.
– If there are faults stored in the engine command unit, they will
appear sequentially on the display.
– Press
←
key.
– Press on the
05 Erase fault memory
on the display.
– Press
06 End the test
function key.
2.3
Adjusting functions and components
Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnosis cable (3 m) -VAS 5051/1- or Diagnosis cable (5 m)
-VAS 5051/3-
Select, in the Diagnosis, Measurement and Information System -
VAS 5051A/52- the “Assisted fault finding”.
After querying all the command units:
– Press
Skip
key.
– Select
Function/component selection
.
– Select
Activation
.
– Select
engine identification codes
.
Fox 2004 ➤
116
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