Engine ID
Edition 12.2009
. Volksw age n n AG
n AG a g e
w l k s o
y V d b
d o e
s n
e i s r o h t u a
o t g u a r a n t
e e
o r a
s s e l
c c
e p
n
u d
t a
n y
e
t t i
l
i a b i l i
m r e
p
t y
t o
w i t
n
s
h
i ,
r
e l
e s p e
o h
w
c
t t
n
i
o
r
o
t
h e
t
r
c
a p
o r r
n i ,
e
c
s
t
n
e
e
s
s s
o p
o
r
u p
f
n f o r
i
l
a i
c r e
m
a
m m
t i
o n i n t h i s
o c r o
e t a v i r p
d
o
c u m
r o f
e
n t .
g n
i y
C o p
p
o
C . t h g
r y i g
i r y p
o c
y b
d e t c e t o r P
h t b y
V l o k s w a g e n A G
.
. Volksw age n n AG
G e n A a g
k s w l k V o
d o oe
s n
y d b
e i s r
o
h t u a
o t g u a r a n t
e e
o r a
s s e l n
c c
e p
u d
t a
n y
e t t
l
i
i a b i l i
m r e
p
t y
t o
w i t
n
s i
h
,
r
e l
e s p e
o h
w
c
t t
n
00 - Technical data
i
o
r
o
t
h e
t
r
c
a p
o
10 - Cylinders, engine block, support, protector 13 - Crankshaft, pistons
r r
n i ,
e
c
s
t
n
e
e
s
s s
o p
15 - Cylinder head, valve control mechanism
o
r
u p
17 - Lubrication system 19 - Cooling system
f
i n
l
a i
f
o
c r e
r m
a
m m
t
i o n i n t h i s
o
c rpump (pre-supply pump) G6 20 - Supply system - tank, Fuel o
e t
a 24 - Supply system - fuel injection v i r
26 - Exhaust system 28 - Ignition system
d
o
c u m
p r
o f
e
n t .
g n
i y
p
o
C . t h g
i r y p
o c
y b
d e t c e t o r P
e n A . G
b y
V
l o k s w a
C o p y r i g h t
g
Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
. Volksw age n n AG
G e n A a g
k s w l k V o
d o oe
s n
y d b
e i s r
o
h t u a
o t g u a r a n t
e e
o r a
s s e l n
c c
e p
u d
t a
n y
e t t
l
i
i a b i l i
m r e
p
t y
t o
w i t
n
s i
h
,
r
e l
e s p e
o h
w
c
t t
n
00 - Technical data
i
o
r
o
t
h e
t
r
c
a p
o
10 - Cylinders, engine block, support, protector 13 - Crankshaft, pistons
r r
n i ,
e
c
s
t
n
e
e
s
s s
o p
15 - Cylinder head, valve control mechanism
o
r
u p
17 - Lubrication system 19 - Cooling system
f
i n
l
a i
f
o
c r e
r m
a
m m
t
i o n i n t h i s
o
c rpump (pre-supply pump) G6 20 - Supply system - tank, Fuel o
e t
a 24 - Supply system - fuel injection v i r
26 - Exhaust system 28 - Ignition system
d
o
c u m
p r
o f
e
n t .
g n
i y
p
o
C . t h g
i r y p
o c
y b
d e t c e t o r P
e n A . G
b y
V
l o k s w a
C o p y r i g h t
g
Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.
FOX 2004 ➤ 3 - Cyl. injection engine - Edition 12.2009
1.1 1.1 1.2 1.2
Engi Engine ne numb number er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engi Engine ne feat featur ures es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volksw age n n AG
n AG a g e
k s w l k V o
1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4
1 1
d o oe
s n
y d b
o t g u a r a n t
Remo Remova vall - indi indica cati tion ons s . . . . . . . . . . . . . . o r. i s e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e .e . . . . . 4 h t o u r Addi Additi tion onal al note notes s and and asse assemb mbly ly work works s s ain in veh vehic icle les s wit with h air air cond condit itio ioni ning ng.. . . . . . . . . . . . . .a c .. . 7 c s e e l Inst Instal alla lati tion on . . . . . . . . . . . . . . . . . u n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p .t a . 7 n d Tigh Tighte teni ning ng torq torque ues s . . . . . . . . . i . e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y l 8 t t i m r e
a b i l i
p
t y
t o
w i t
n
s i
h
,
1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4
r
e l
Part Part I - Op Oper erat atin ing g Pol Polyy-V V bel b eltt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o h w Part Part II - Ope Opera rati ting ng th the e cha chain in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n Poly Poly-V -V belt belt - rem remov ove e and and oinst instal alll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cont Contro roll box box - remo remove ve and and p a ins insta tall ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
r
t
r
e s
11 p e c 11 o 13 h e 15 o t t
t
c
r r
n i , s
2.1 2.1 2.2 2.2 2.3 2.3
e
c
e
Cran Cranks ksha haft ft seal seals s . . . . . o . .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. p Cran Cranks ksha haft ft seal seal (pul (pulle ley y sid side) e) - rep repla lace ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . u p Cran Cranks ksha haft ft seal seal (flyw (flywhe heel el a side side)) - repl replac ace e . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . s
r
l
i
c r e
e
s s
o
f
i n
f
o
r m
a
m m
t
i o n i n t h i s
o c r o
1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.6
t
n
18 19 21
e
t Cyli Cylind nder er head head - dis disas asse semb mble le and an d ass assem embl ble e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o d24 a v i r p Cyli Cylind nder er head head - remo remove ve and and ins insta tall ll o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m . u c 25 r f e Dist Distri ribu buti tion on time times s - chec check k . . . . . . g . n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t . n. . 28 i y C p Roll Roller er chai chains ns - rem remov ove e and and inst instal alll . . o . C . t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r y . p. o. . . . 30 . i g h h Dist Distri ribu buti tion on time times s - adju adjust st . . . . . . . . . . . g . i r . p . . . . . . . . . . . . . . . . . . . . . . . . . . . . y b . t . . . . . . . . 32 y o V c o l y k Comp Compre ress ssio ion n - chec check k . . . . . . . . . . . . . . . . . . . . b . e . t c . e . . . . . . . . . . . . . . . e . g a . w . s . . . . . . . . . . . . . 35 d t o r P
n A . G
2.1 2.1 2.2 2.2 2.3 2.3 2.4 2.4 2.5 2.5
Cams Camsha haft ft mech mechan anis ism m - repa repair ir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cams Camsha haft ft - che check ck axia axiall cle clear aran ance ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valv Valve e sea seatt - trim trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valv Valve e gui guide des s - chec check k . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . Valv Valve e ste stem m sea seall - repl replac ace e . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. ..
1.1 1.1 1.2 1.2 1.3 1.3
Engi Engine ne oil oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Oil Oil cra crank nkca case se - rem remov ove e and and inst instal alll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Oil Oil pre press ssur ure e and and Oil Oil pres pressu sure re swit switch ch F1 - che check ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.6
Cool Coolin ing g sys syste tem m com compo pone nent nts s on on bod body y sid side e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Cool Coolin ing g sys syste tem m com compo pone nent nts, s, engi engine ne side side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Cool Coolin ing g sys syste tem m hos hose e con conne nect ctio ion n dia diagr gram am . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Cool Coolin ing g sys syste tem m - drai drain n and and repl replen enis ish h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Radi Radiat ator or - remo remove ve and and ins insta tall ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Wate Waterr pum pump p - remo remove ve and and ins insta tall ll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents
37 40 40 42 43
i
