Volkswagen Fox (2004 year). Manual — part 27

5 - Intake manifold pressure

sensor -G71- with Intake mani‐

fold temperature sensor -G72-
6 - Support
7 - 5 Nm
8 - Hose
9 - Tube
10 - From exhaust gas recircu‐

lation valve
11 - From the air filter
12 - From head cover
13 - Tube
14 - Exhaust manifold
15 - Tube
16 - Support

❑ From tube.
❑ Bolted to crankcase.

Fox 2004 ➤

1. Overcharge system with turbocharger

105

Maintaining the direct injection Diesel

system

The direct injection diesel system command unit has a fault mem‐

ory. Before performing repairs, and for fault location, refer to the

fault memory

⇒ page 115

.

Safety measures

⇒ page 107

.

Cleaning rules

⇒ page 107

.

1.1

Installation locations - overview

Components A to D are not shown in the illustration.

A - Brake pedal switch -F47- or

Brake light switch -F-

❑ Together in one case, in

the feet compartment,

on the brake pedal.

B - Accelerator pedal position

sensor -G79- and Sensor 2 of

accelerator pedal position -

G185-

❑ At the feet compart‐

ment, on the accelerator

pedal.

C - Clutch pedal switch -F36-

❑ In feet compartment, on

clutch pedal.

D - Fuel pressure regulator

❑ In fuel pump.

1 - Valve blocking

❑ Vacuum hose connec‐

tion diagram

⇒ page 121

.

2 - Exhaust gas recirculation

valve (mechanical)

❑ With intake manifold

valve.

3 - Pressure regulating valve

❑ To crankcase vent.

4 - Intake manifold

❑ Intake manifold pres‐

sure sensor -G71- with

Intake manifold temper‐

ature sensor -G72- .

5 - Direct injection diesel sys‐

tem control unit -J248-

❑ With Altitude sensor -F96- .
❑ Replace

⇒ page 115

.

Fox 2004 ➤

106

⇒ page 95

.

9 - Vacuum pump
10 - Connector

❑ For Pump / injector valve of cylinder 1 -N240- ... Pump / injector valve of cylinder 4 -N243- .

11 - Fuel temperature sensor -G81-
12 - Engine speed sensor -G28-
13 - Thermostat valve
14 - Glow plugs
15 - Hall Sensor -G40- Hall (G40) Sensor

❑ For the camshaft position.

16 - Fuel filter

1.2

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 their original

positions.

♦ Provide easy access to all 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.
To prevent injuries to persons and/or damages to the injection

system and glow plugs, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐

connecting test cables for injection and glow plugs.

♦ If the engine is to be turned over at starting speed, without

starting, e.g. to check compression, disconnect injector con‐

nector on cylinder head.

♦ Check if the vehicle has code radio; if so, request respective

anti-theft code before disconnecting the battery.

♦ Only disconnect and connect the battery when the ignition is

switched off; otherwise, the direct injection diesel command

system unit may be damaged.

1.3

Cleanliness rules

When servicing the fuel supply/injection system, pay attention to

the following cleanliness rules:

Fox 2004 ➤

1. Maintaining the direct injection Diesel system

107

♦ Place all the parts removed on clean surface and cover them.

Do not use cloth that releases lint!

♦ If repair work is not to be carried out immediately, open com‐

ponents opened must 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.).

♦ With system open: If possible, avoid using compressed air. If

possible, do not move the vehicle.

♦ Also, ensure that no diesel runs onto the cooling system ho‐

ses. Hoses coming in contact with fuel must be cleaned im‐

mediately. Damaged hoses should be replaced.

1.4

Intake manifold valve - repair

The intake manifold valve closes for approx. 3 seconds when

stopping the engine, and then opens again. This reduces the stop

jerking movement.

1 - Intake manifold
2 - Intake connection flange

❑ With exhaust gas recir‐

culation valve.

3 - Sealing ring

❑ Replace.

4 - 10 Nm
5 - From the intercooler
6 - Intake manifold valve motor

-V157-
7 - 10 Nm

Fox 2004 ➤

108