GEAR

Service
AG. Volkswagen AG d
Workshop Manual
agen oes
olksw not
V gu
d by ara
ise nte
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ ,
or eo
h
aut ra
s c
SpaceFox 2006 ➤ , SpaceFox 2011 ➤
s
ce
e
nl
pt
du
an
itte
4 - Cyl. injection engine (1.6 l)
y li
erm
ab
ility
ot p
BJA BAH BPA BLH CCR

A CFZA
wit
Engine ID
, is n
h re
hole
spec
Edition 09.2017
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
AG. Volkswagen AG d
24 - Mixture preparation - injection lksw
agen oes
not
o
yV gu
26 - Exhaust system ised b ara
nte
or eo
28 - Ignition system
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2017 Volkswagen AG, Wolfsburg BRA5R007320

AG. Volkswagen AG d
agen oes
olksw not
Fox 2004 ➤ , Fox 2010 ➤ , Fox d2014by
V
➤ , SpaceFox 2006 ➤ , SpaceFox gu
ar 201 ...
ris 4 - Cyl. injection engine (1.6 l) - Editionan09.2017
e
tee
tho
or
au ac
ss
Contents
ce
le
un
pt
an
d
itte
y li
erm
ab
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ility
ot p
wit
is n
1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
h re
ole,
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
spec
urposes, in part or in wh
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
t to the co
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Engine - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
rrectne
1.1 Removal - recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Engine - fasten to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ss o
1.3 Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
cial p
f in
1.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
form
mer
1.5 Engine and gearbox support set - align . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
atio
m
1.6 Power-drive group supports, (torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

o
n
c
i
or
n
1.7 Additional notes and installation works in vehicles with air conditioning . . . . . . . . . . . . . . 17
thi
te
sd
iva
o
pr
c
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
um
r
fo
en
ng
t.
1 Engine - assembly and disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
yi Co
Cop py
1.1 Seal lid - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
t. rig
gh ht
yri by
1.2 Poly-V belt - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
op Vo
by c lksw
cted
1.3 Poly-V belt (elastic) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
agen
Prote AG.
2 Crankshaft and flywheel flanges - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.1 Flywheel - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Crankshaft seal (pulley side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 Crankshaft flange (flywheel side) - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3 Crankshaft - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Identifying engine bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Colour codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3 Crankshaft - dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Pistons and connecting rods - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Piston and cylinder - dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1 Cylinder head - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Toothed belt semi-automatic tensioning pulley - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Toothed belt - remove and install, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3 Cylinder head - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.4 Compression - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Camshaft - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Camshaft - check axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.2 Valve seat - trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.3 Camshaft seal - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.4 Camshaft and cylinder head cover - removal and installation . . . . . . . . . . . . . . . . . . . . . . 81
2.5 Valve guides - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.6 Valve stem sealant - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Lubrication system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Lubricating system components - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.3 Oil pan- remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.4 Oil filter - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.5 Oil pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Contents i
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ , SpaceFox 201 ...
4 - Cyl. injection engine (1.6 l) - Edition 09.2017
1.6 Oil pressure switch F1 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.7 Oil pressure and Oil pressure switch F1 - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1 Cooling system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1 Cooling system components on the body side - assembly overview . . . . . . . . . . . . . . . . . . 103
1.2 Cooling system components on the engine side - assembly overview . . . . . . . . . . . . . . . . 105
1.3 Hose connection diagram for cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.4 Cooling system - drainage and replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.5 Cooling system - check air-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.6 Radiator - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.7 Water pump - remove and install . . . . . . . . .n .AG . .. V.o.lk.sw
. a. g.e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . 122
age does
ksw not
Vol
20 - Fuel supply system . . . . . . . . . .se.d . . . . . . . . . . . . . . . . . . . . . . .gu.ar.an. . . . . .
by . . . . . . 125
ri te
1 Fuel supply system components
utho - removal and installation . . . . . . . . . . . .e o. r . . . . ....... 125
a a
1.1 Fuel tank components withssaccessories and fuel filter - assembly overview . .c . . . ....... 125
ce
e
1.2 Safety measures regarding work on the fuel supply systems . . . . . . . . . . . . . . . . . . . . . . 128
nl
pt
du
an
itte
1.3 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
y li
erm
ab
1.4 Quick connection “Pop Top” - disconnection and connection . . . . . . . . . . . . . . . . . . . . . . 129
ility
ot p
1.5 Fuel pump for cold start V263 - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 131
wit
, is n
h re
1.6 Fuel pump (pre-supply pump) G6 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
hole
spec
1.7 Fuel gauge sensor G - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
es, in part or in w
1.8 Fuel reservoir - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
t to the co
1.9 Fuel pump (pre-supply pump) G6 - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
2 Engine power electronic adjustment (electronic accelerator) - check . . . . . . . . . . . . . . . . 150
rrectness of i
2.1 Electronic accelerator system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
l purpos
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
nform
ercia
3.2 Activated charcoal filter system components - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.3 Fuel tank ventilation - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
m
at
om
ion
c
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 in t

or
his
ate
1 Injection system - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

do
priv
cum
or
1.1 General instructions regarding the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

f
en
ng
t.
1.2 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
yi Co
op py
1.3 Injection components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
t. C rig
gh ht
yri by
1.4 Intake manifold - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
cop Vo
by lksw
cted
1.5 Fuel distributor with injectors - removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
agen
Prote AG.
1.6 Air filter - disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.7 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.8 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Component checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.1 Injection valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Residual pressure and fuel pressure regulator - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3 READINESS code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.1 Creating and Interpreting the READINESS code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4 Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.1 Engine control unit J623 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.2 Components - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.3 Event memory in Engine control unit J623 - reference and erase . . . . . . . . . . . . . . . . . . . . 182
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1 Removing and installing exhaust system parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.1 Intake manifold, front exhaust tube with catalytic converter and installation parts . . . . . . . . 185
ii Contents
1.2 Muffler with supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1 Ignition system: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.1 General instructions regarding the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.2 Ignition system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Contents iii
lkswage es n
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 by V ➤ , SpaceFox 2006 ➤ , SpaceFox
o ot g
ua 201 ...
ed ran
4 - Cyl. injection engine (1.6 l)ho-r Edition 09.2017
is tee
ut or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
iv Contents
00 – Technical data
1 Technical Data
(VRL010825; Edition 09.2017)
1.1 Engine number

The engine number (“code letters” and the “serial number”) is en‐
graved on the cylinder block-arrow-, under the thermostat body.
The engine number is comprised of nine digits (alphanumerical)
at most. The first part (max. of 3 identification letters) represents
“the engine ID letters”; the second part (6 characters) is the “serial
number”. If more than 999,999 engines with the same engine co‐
des are produced, the first of the six digits is replaced by a letter.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
Additionally, there is a sticker -arrow- containing the “engine co‐

nl
pt
du
an
des” and “series number”on the mechanical distribution cover.
itte
y li
erm
ab
The engine codes are also shown on the vehicle data plate.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.2 Engine characteristics

nform
mercia
at
Engine codes BAH (petrol) BLH(petrol) BJA (Total BPA (Total CCRA (To‐ CFZA(pet‐
om
io
flex) flex) tal flex) rol)

n
c
in t
or
his
e
Production 10/2003 to 11/2003 to 10/2003 to 10/2004 to 04/2008 ► 11/2008 ►

at
do
riv
11/2008 11/2010 10/2004 06/2008

p
cum
or
Cylinder 1599 1599 1599 1599 1598 1598

f
cm3
en
ng
t.
yi
volume
Co
Cop py
t. rig
Power hp(kW)/ 101.0 (74.0)/ 101.0 (74.0)/ 101.0 (74.0)/ gh
101.0 101.0 101.0
ht
yri by
(petrol) rpm 5750 5500 5750 (74.0)/5750 (74.0)/5250 (74.0)/5250
cop Vo
by lksw
cted agen
Power hp(kW)/ --- --- 103.0 (76.0)/ 103.0 104.0 ---
Prote AG.
(etha‐ rpm 5750 (76.0)/5750 (76.0)/5250

nol)
Torque Nm(mkgf)/ 140.0 (14.3)/ 140.0 (14.3)/ 140.0 (14.3)/ 140.0 151.0 143.0
(petrol) rpm 3250 3250 3250 (14.3)/3250 (15.5)/2500 (14.6)/2500
Torque Nm(mkgf)/ --- --- 142.0 (14.5)/ 142.0 153.0 ---
(etha‐ rpm 3250 (14.5)/3250 (15.6)/2500
nol)
Diame‐ ∅ mm 76.5 76.5 76.5 76.5 76.5 76.5
ter
Stroke mm 87.0 87.0 87.0 87.0 87.0 87.0
Compression rate 10.8:1 10.8:1 10.8:1 10.8:1 12.0:1 10.8:1
1. Technical Data 1
Engine codes BAH (petrol) BLH(petrol) BJA (Total BPA (Total CCRA (To‐ CFZA(pet‐
flex) flex) tal flex) rol)
Fuel Regular un‐ Regular un‐ Bi-fuel (Un‐ Bi-fuel (Un‐ Bi-fuel (Un‐ Regular un‐
leaded petrol leaded petrol leaded gaso‐ leaded gas‐ leaded gas‐ leaded pet‐
line/Ethanol) oline/Etha‐ oline/Etha‐ rol
nol) nol)
Injection, ignition Bosch Bosch Bosch Bosch Bosch Bosch
ME 7.5.10 ME 7.5.102) ME 7.5.10 ME 7.5.101) ME 7.5.106) ME 7.5.307)
7)
Knock control 1 knock sen‐ 1 knock sen‐ 1 knock sen‐ 1 knock 1 knock 1 knock
sor sor sor sensor sensor sensor
Self-diagnosis yes yes yes yes yes yes
Lambda adjustment 1 probe 2 probes3) 1 probe 1 probe 1 probes5) 2 probes4)
Volkswagen AG
Catalytic converter yes swagen AG.yes doyes
es yes yes yes
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
1) ME 7.5.20 as of 09/2006.
a c
ss
ce
e
2) ME 7.5.20 as of 02/2006.
nl
pt
du
an
itte
3) Mexico version
y li
erm
ab
4) 2 lambda probes for the Argentinean version only
ility
ot p
wit
, is n
5) 2 lambda probes exclusively for the Novo Fox and Nova SpaceFox/Suran ver‐
h re
sions
hole
spec
6) 4GV for the SQ200 gearbox (gear selection mechanism)
es, in part or in w
t to the co
7) 9GV as of 04/2013.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2 Rep. gr.00 - Technical data

10 – Removing and installing engine

1 Engine - remove and install
Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
♦ Lifting tackle - 2024A-

t
sd
iva
o
r
rp
cu
♦ Mounting bracket - VW 540-

o
m
f
en
ng
t.
yi Co
♦ Hydraulic hoist - VAG 1202A- . Cop py
rig
ht ht
rig
♦ Oil trap - VAG 1306- py by
co Vo
by lksw
cted
♦ Torque wrench - 5 to 50 Nm ( 1/2” drive) - VAG 1331- .
agen
Prote AG.
No illustration:
♦ Lifting eyelets, replacement part number: Support - 030 103
390 F- (pulley side), Support - 030 103 390 G- (inertial flywheel
side).
♦ Grease - G 000 100- and Grease - G 000 150- (vehicles with
manual gearbox)
♦ Cable tie.
1. Engine - remove and install 3

lkswage es n
o ot g
byV ua
ed ran
Fox 2004 ➤ , Fox 2010 ➤ , Foxh2014 oris ➤ , SpaceFox 2006 ➤ , SpaceFox 201 tee ...
t or
4 - Cyl. injection engine (1.6 l)s a-u Edition 09.2017 ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Torque Wrench - 40 to 200 Nm ( 1/2” drive) - VAG 1332-

♦ Support for VW 643 or VW 643/1 - VW 313- or Rotary stand
for engine and gearbox - VAS 6095-
♦ Gearbox or engine + gearbox assembly jack or VAG 1383A
set - EQ 7081-
♦ Device - T02001-
♦ Standard-type clamp pliers - VW 5162 (VWB) - ou - VAS
5024A- , or Standard-type clamp pliers - VAS 6340-
♦ Adaptor bushing - T02002-
4 Rep. gr.10 - Removing and installing engine

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ 5-Step ladder - VAS 5085-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Sealing plug kit (engine) - VAS 6122-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
♦ Pipe sealing tool - T10249-
do
r
rp
cum
fo
1.1 Removal - recommendations
en
ng
t.
yi Co
Cop py
t. rig
gh ht
WARNING pyri by
Vo
co lksw
by
cted agen
Prote AG.
For vehicles with “I-motion” automated shift gearbox, de‐
pressurize the hydraulic system of the gear selection mecha‐
nism ⇒ 5-speed automated shift gearbox (ASG) 0C3.; Rep.
gr. 34 ; Drive, housing .
Note
Check whether the vehicle has a coded radio. If so, request the
anti-theft code before disconnecting earth wire from the Battery -
A- .
– The engine is removed from the lower part of the vehicle with
the gearbox.
– With ignition off, disconnect earth wire from the Battery - A- .
– All cable clamps that open or break during engine removal
must be replaced and installed in the same locations when
engine is reinstalled.
– Remove the air filter housing ⇒ page 168 .
– Remove the Battery - A- ⇒ Electric equipment; Rep. gr. 27 ;
Starter, alternator, battery .

– Remove the Battery - A- tray ⇒ Electrical equipment; Rep. gr.

27 ; Starter, alternator, battery .
The cooling system is under pressure when the engine is hot.
Thus, it is necessary to reduce the pressure before conducting
repairs.
WARNING
Hot vapours may escape when the coolant reservoir is opened;

cover it with a cloth and open carefully.
WARNING
Fuel supply hose is under pressure. Wrap hose connections in

cloth prior to loosening. Next, eliminate pressure by carefully
removing hose. en AG. V
olkswagen AG
wag does
olks not
byV gu
ara
ed nte
ris
ho e
– Loosen the fuel
au supply pipes 1 (press
t the key to unlock it). or a
(BAH, BLHssand CFZA Engines only). c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Loosen the fuel supply pipes 1 (press the key to unlock it).
(BJA, BPA and CCRA Engines only).
– Loosen on the Magnetic valve for activated charcoal tank -
N80- the hose connected to the intake manifold.
– Close the lines with the Pipe sealing tool - T10249- , in order
to prevent impurities from entering the supply system.
– Follow cleaning rules ⇒ page 129 .
. Volkswagen AG
gen AG does
– Drain cooling system ⇒ page 110 V.olkswa not
gu
y
db ara
Mechanical transmission: orise nte
eo
h
ut ra
– Release the gearbox shifting
ss a
mechanism ⇒ 5-speed manual c
gearbox (02T and 0AP); Rep. gr. 34 ; Drive, housing .
ce
e
nl
pt
du
an
– Remove clutch operating receptor cylinder: ⇒ 5-speed manual
itte
y li
erm
gearbox (02T and 0AP); Rep. gr. 30 ; Clutch - command sys‐
ab
ility
tem .
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Clutch pedal must not be activated.
rrectness of i
“I-motion” automated gearbox:
l purpos
– Disconnect the connectors of electrical harness of gear selec‐

tor mechanism ⇒ 5-speed automated gearbox (ASG) 0C3;
Rep. gr. 34 ; Drive, housing .
nf
ercia
or
Continued for all vehicles:
m
m
atio
m
– Loosen or disconnect the following components:

o
n in
or c
thi
e
♦ Remove the brake servo valve with the aid of the Pliers -
t
sd
iva
AG3392- .
o
r
rp
cu
o
m
f
en
ng
♦ Hose for Cold start valve - N17- on throttle housing.

t.
yi Co
op py
♦ Connector for Intake manifold pressure sensor - G71- and In‐
t. C rig
gh ht
yri
take air temperature sender - G42- . p by
o Vo
by c lksw
cted agen
♦ Connector for the Ignition transformer - N152- , Sensor Hall - Prote AG.
G40- and Throttle valve control unit - J338- .
♦ Connector for the Coolant temperature sensor - G62- and the
Oil pressure switch - F1- .
♦ Injection valve connectors.
♦ Lambda probe - G39- connector.
♦ Remove the upper and lower cooling system hoses from the
coolant expansion tank.
♦ Loosen the upper radiator hose.
♦ Remove the expansion valve hoses ⇒ Heating, ventilation, air
conditioning; Rep. gr. 87 ; Air conditioning .
♦ Remove the front wheels.
♦ Remove the left and right protector for the front wheel hous‐
ings.
♦ Remove the engine compartment lower noise insulation ⇒
General body repairs, exterior; Rep. gr. 50 ; Body - Front sec‐
tion .
♦ Loosen the lower radiator hose.
♦ Remove the Poly-V belt ⇒ page 24 .

♦ Remove the power steering oil pump and put it aside, together
with the local hoses⇒ Chassis, axles, steering; Rep. gr. 48 ;
Steering .
♦ Connector for the Engine speed sensor - G28- (next to the
intake manifold).
♦ 2-pole connector for Knock sensor 1 - G61- (intake manifold
side).
♦ Loosen the engine harness from the brackets and support it
on the front end.
♦ Remove/disconnect and release all gearbox electric cables,
Starter - - Generator (Alternator) - - and air conditioning com‐
pressor.
♦ Remove the negative cable that connects the left front longi‐
olkswagen AG
tudinal member gearbox from the
w a en AG. V
glongitudinal member. does
s k not
Vol g
♦ Disconnect the connector by
ed for the Lambda Probe after the cat‐ ran
ua
alyst - G130- . oris tee
th o
au ra
c
♦ Remove front exhaust
ss pipe ⇒ page 185 .
ce
le
un
pt
– Put the lock carrier in service position ⇒ General body repairs,
an
d
itte
y li
exterior; Rep. gr. 50 ; Body - Front section .
rm
ab
pe
ility
– Remove the pendulum support -arrows-.
ot
wit
, is n
h re
hole
Until December 9, 2007
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
From December 10, 2007

do
r
rp
cum
fo
Vehicles with air conditioning:

en
ng
t.
yi Co
op
– Remove air conditioning compressor: ⇒ Heating, ventilation,
C py
ht. rig
air conditioning; Rep. gr. 87 ; Air conditioning (without dis‐
rig ht
py by
o Vo
connecting the hoses). by c lksw
cted agen
Prote AG.
– Observe additional indications and installation works
⇒ page 17 .
– Remove the Generator (Alternator) - C- .
– Remove the power steering hydraulic oil pump anchoring
bracket, Generator (Alternator) - C- and air conditioner com‐
pressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioning .
– Loosen right and left drive shafts on gearbox and fasten them
to the body ⇒ Chassis, axles, steering; Rep. gr. 40 ; Front
suspension .

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Fox 2004 ➤ , Fox
au 2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ , oSpaceFox
th
ra 201 ...
c
4 - Cyl. injection engine (1.6 l) - Edition 09.2017 ss
ce
le
un
pt
an
d
– Support engine and gearbox with the Gearbox or engine +
itte
y li
gearbox assembly jack or VAG 1383A - EQ 7081- , Device -
rm
ab
pe
ility
T02001- and Glove - T02002- . ot
wit
, is n
– Remove the screws from the gearbox support -B- -arrows- and
h re
hole
from the engine's support -A- -arrows-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Lower the set enough to free it from the gearbox mount so
there is no interference by the selector mechanism and the
constant-velocity joint.
– Displace the engine and gearbox assembly to the front.

– Remove the engine and gearbox

en AG. V
olkassembly.
swagen AG
ag does
ksw n
– Install lifting eyelets Vol
by on the cylinder head. Tightening
ot g torque:
ua
25 Nm. ir se
d ran
te
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Fasten with the Lifting tackle - 2024A- as described below and
orm
raise it slightly with the hoist:
m
atio
om
Pulley side: position -3- of the vertical rod. Orifice on the sustain‐
n in
or c
ing bar in position -1-.
thi
te
sd
iva
Flywheel side: position -3- of the vertical rod. Orifice on the sus‐
o
r
rp
cu
o
taining bar in position -5-.

m
f
en
ng
t.
yi Co
Cop py
. rig
WARNING
t
gh ht
pyri by
Vo
co lksw
by
cted
Use safety locks on the hooks and pins -arrows-.
agen
Prote AG.
Note
♦ Positions numbered -1...8- on the lifting bar are ordered from

the pulley side.
♦ The holes in the supports are counted from the hook.
1.2 Engine - fasten to assembly stand

Special tools and workshop equipment required
♦ Support for VW 643 or VW 643/1 - VW 313- or Rotary stand
for engine and gearbox - VAS 6095-
To perform installation work, fasten the engine on the Support for

VW 643 or VW 643/1 - VW 313- or Rotary stand for engine and
gearbox - VAS 6095- .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Fox 2004 ➤ , aFox
ut
ho
2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤e,orSpaceFox ac
201 ...
4 - Cyl. injection engine (1.6 l) - Edition 09.2017 ss
ce
le
un
pt
an
d
1.2.1 Operation sequence
itte
y li
rm
ab
pe
ility
– Separate gearbox from engine.
ot
wit
, is n
– Remove the inertial flywheel.
h re
hole
spec
– Remove intermediate plate.
es, in part or in w
t to the co
– Fasten the engine with the Support for VW 643 or VW 643/1
- VW 313- or Rotary stand for engine and gearbox - VAS
6095- .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
1.3 Installation notes
Co
Cop py
t. rig
gh ht
yri
Installation is carried out in the reverse sequence to the removal,
p by
co Vo
by lksw
considering the following: Prote
cted AG.
agen
WARNING
Remember the following when performing installation work,

especially inside the engine compartment where there is little
space:
♦ 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.
♦ Allow easy access to all the moving or hot parts.
– Check the clutch roller bearing for wear and replace if neces‐
sary ⇒ Clutch, gearbox; Rep. gr. 34 ; Drive, housing .
– Clean and lightly lubricate the splines of the input shaft with
Grease - G 000 100- .
– If necessary, check that the clutch disc is centralized.
– Check that the guides for coupling the engine and gearbox are
placed on the engine block and, if necessary, install them.

– Install the intermediate plate on the sealing flange and move

it towards the sleeves -arrows-.
– When the set is installed, pay attention to ensure the free pas‐
sage of the selector mechanism and the drive shaft.
– Align the engine, moving it slightly so that the supports fit with‐
out tension. gen AG
. Volkswagen AG
d a oes
ksw not
Vol gu
d by ara
ise nte
Note thor eo
au ra
c
ss
Tightening torque for the assembly .
ce
e
nl
pt
du
an
itte
y li
– Install drive shafts: ⇒ Chassis, axles, steering ; Rep. gr. 40 ;
erm
ab
Front suspension .
ility
ot p
wit
, is n
Vehicles with air conditioning:
h re
hole
spec
– Remove the air conditioning compressor ⇒ Heating, air con‐
es, in part or in w
ditioning; Rep. gr. 87 ; Air conditioning .
t to the co
– Install Poly-V belt ⇒ page 24 .
Mechanical transmission:
rrectness of i
– Install the hydraulic clutch mechanism ⇒ 5-speed manual
l purpos
gearbox (02T and 0AP); Rep. gr. 30 ; Clutch - command sys‐

tem ().
nform
ercia
– Install gear shifting mechanism⇒ Automatic / manual gearbox;

m
Rep. gr. 34 ; Drive, housing .

at
om
ion
c
in t
“I-motion” automated gearbox:

or
his
ate
– Connect the connectors of electrical harness of gear selector

do
priv
mechanism ⇒ 5-speed automated gearbox (ASG) 0C3; Rep.

um
for
en
g
gr. 34 ; Drive, housing .

n
t.
yi Co
op py
t. C rig
gh ht
pyri by
Vo
– Electrical connections and their arrangement: ⇒ Current flow
o
by c lksw
cted agen
diagrams, Electrical fault finding and Fitting locations.
Prote AG.
– Install front exhaust pipe onto exhaust manifold ⇒ page 185 .

– Install engine compartment lower noise insulation.
– Fill cooling system.
– Remove lifting eyelets from the engine cylinder head.
– Install cooling system pipes on engine cylinder head. Tight‐
ening torque: 25 Nm.
– Install air filter set ⇒ page 168 .
– Adjust the Engine control unit - J623- to the Throttle valve
control unit - J338- ⇒ page 182 .
– Perform the basic adjustment for the initial position of the
clutch and the gear lever and consult the event memory⇒ Ve‐
hicle diagnostic tester.
– Carry out a test run and check the event memory
⇒ page 182 .
1.4 Tightening torques

Location Tightening tor‐
ques
Bolts, nuts M6 10 Nm
M8 20 Nm

Location Tightening tor‐

ques
M 10 45 Nm . Volkswagen AG
gen AG does
M 12 60 Nm Volkswa not
by gu
ara
Exhaust pipe on the exhaust manifold 40risNm
ed
nte
ho eo
aut ra
ss c
ce
le
Note
un
pt
an
d
itte
y li
Tightening torque for the assembly housing ⇒ page 16 .
erm
ab
ility
ot p
wit
is n
h re
ole,
WARNING
spec
t to the co
Always replace self-locking nuts and bolts subject to angular
torque
rrectne
1.5 Engine and gearbox support set - align
ss o
cial p
f inform
♦ Support device - 10-222A- with Claws - 10-222 A/1- or the
mer
Adaptor - T02007-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Torque wrench - 5 to 50 Nm ( 1/2” drive) - VAG 1331-

Torque Wrench - 40 to 200 Nm ( 1/2” drive) - VAG 1332-
WARNING
Before loosening the screws, support the aggregates with the

Support device - 10-222A- .
1.5.1 Power-drive unit supports (engine)

-a- = 3.0 mm
– When installing the new screws -A and B-, in order to prevent
the assembly from moving, position first all the screws, then
apply the torque with the torque wrench, and then the angle
torque with a force cable.
Note
Fastening screws -B-of the gearbox mounting must be handled

with care when the final torque is applied, so as not to displace
the assembly. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
d by ua
ran
e
ris tee
1.5.2 Power-drive group supports (gearbox) au
tho or
ac
ss
ce
le
un
the assembly from moving, position first all the screws, then pt
an
d
itte
apply the torque with the torque wrench, and then the angle y li
erm
torque with a force cable. ab

ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
Fastening screws -B-of the gearbox mounting must be handled

with care when the final torque is applied, so as not to displace
the assembly.
rrectness
Note
o
cial p
f inform
The power unit support fastening screws are expansion screws

mer
and must be replaced.

atio
om
n
c
i
or
n thi
te
sd
a
WARNING
iv
o
pr
cum
r
fo
en
ng

t.
yi Co
torque Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.6 Power-drive group supports, (torque)
Note
The power unit support fastening screws are expansion screws

and must be replaced.
WARNING

torque
1.6.1 Power-drive unit supports (engine)

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole

spec
es, in part or in w
A8) = 20 Nm + 90°
t to the co
B 8)= 30 Nm + 90°
rrectness of i
8) Replace.

l purpos
nf
ercia

orm
m
atio
om
n in
or c
thi
te
sd
iva
1.6.2 Power-drive group supports (gearbox)

r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


A9) = 50 Nm + 90°
B 9)= 40 Nm + 90°
9) Replace.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
or
1.6.3 Pendulum support (torque restrictor)
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f in

form
mer
A10) = 30 Nm + 90°. B.
atio
om
n
c
B 10)= 40 Nm + 90°
i
or
n thi
te
sd
a
10) Replace.
iv
o
pr
cum
r

fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.7 Additional notes and installation works

in vehicles with air conditioning
WARNING
The cooling gas circuit for the air conditioner should not be
opened.
Note
To avoid damage to the condenser and cooling gas hoses, do not

kink, twist nor overstretch the hoses.
To remove and install the engine without opening the cooling gas
loop:
– Remove cooling gas hose clamp(s).

– Remove the Poly-V belt ⇒ page 24 .

– Install front end in the service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - Front section .
– Move the panel with radiator and condenser to the front in such
a way that the coolant gas hoses are not stretched.
– Remove the air conditioning compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioning .
– Fasten the compressor to the body so that the cooling gas
tubes/hoses are not subject to tension.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

13 – Crankshaft group
1 Engine - assembly and disassembly
Note
♦ To carry out assembly works, fasten the engine on the as‐

sembly stand, using the Support for VW 643 or VW 643/1 -
VW 313- or Rotary stand for engine and gearbox - VAS 6095- .
Volkswa
♦ It is necessaryswto
agecarefully
n AG. clean thedoil
gen AG
oes ducts and to replace
the oil filter by if, when servicing the engine, significant
Volk not
gu amounts
of metalir se particles and detached particles are found
d ara
nte in the oil,
due ut to abrasion or wear resulting from seizing (fororinstance,
ho e
sfrom the connecting rods or bearing shells). This procedure
s a ac
prevents any consequential damage.
ce
e
nl
pt
du
an
♦ Lubricate all supporting and sliding surfaces prior assembly.
itte
y li
erm
ab
ility
ot p
wit
, is n
WARNING
h re
hole
Always replace self-locking nuts and bolts subject to angular spec

es, in part or in w
torque t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Engine - assembly and disassembly 19

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
I ⇒ page 20
II ⇒ page 22
Part I
20 Rep. gr.13 - Crankshaft group

1 - Upper cover to mechanical

distributor
2 - Toothed belt
❑ Mark the spinning direc‐ agen AG. Volkswagen AG do
tion before the removal. Vol
ksw es n
ot g
by ua
❑ Check for wear.ris ed ran
tee
ho
❑ Do not bend. aut or
ac
ss
❑ Removal, installation
ce
e
nl
pt
and adjustment
du
an
itte
⇒ page 59 .
y li
erm
ab
ility
3 - 20 Nm + 90°
ot p
wit
, is n
❑ Replace after every re‐
h re
moval.
hole
spec
❑ To loosen and tighten,
es, in part or in w
t to the co
immobilize the camshaft
gear with the Special
wrench - 3036- .
rrectness of i
4 - Camshaft gear
l purpos
❑ Check the fastening

during installation.
nform
ercia
❑ Check the installation

position of toothed belt
m
at
⇒ page 59 .
om
ion
c
in t
r
5 - 10 Nm
o
his
ate
❑ Apply Liquid sealant - do

priv
c
D000 600 A2- .
um
for
en
ng
t.
yi
6 - Mechanical distribution rear
Co
op py
cover
t. C rig
gh ht
pyri by
Vo
7 - Water pump
o
by c lksw
cted agen
Prote
❑ Replace the sealing
AG.
gasket if it is damaged.
❑ In case of damages and
leaks, replace the entire
pump together with the sealing.
❑ Check that it turns smoothly.
❑ Removal and installation ⇒ page 122 .
8 - Toothed belt tensioning pulley
❑ Check ⇒ page 58 .
❑ Drive belt: removal, installation and adjustment ⇒ page 59 .
9 - 23 Nm
10 - 20 Nm
11 - Engine support
12 - Crankshaft gear
❑ Check installation position of toothed belt ⇒ page 59 .
13 - 50 Nm
14 - 10 Nm
15 - Crankshaft pulley
❑ Check the fastening during installation.
❑ Remove and install of Poly-V belt ⇒ page 24 .

16 - 15 Nm + 40°
❑ Replace after every removal.
17 - Poly-V belt
❑ Mark the spinning direction before the removal.
❑ Poly-V belt trajectory ⇒ page 27 . wage
es ks not
Vol g
18 - 90 Nm + 90° ed
by ua
ran
ris tee
❑ Replace after every removal. utho
or
a ac
❑ To loosen and tighten, use Wrench - 3415- .
ss
ce
e
nl
❑ Tightening continuation can be carried out in several steps.
pt
du
an
itte
y li
❑ Tightening angle can be measured with a common protractor, for example, Hazet 6690.
erm
ab
ility
ot p
19 - Lower cover to the mechanical distributor
wit
, is n
h re
hole
spec
Part II
es, in part or in w
t to the co
Note
rrectness of i
Clutch repairs: ⇒ Clutch and gearbox; Rep. gr. 30 ; Clutch -
l purpos
command system .
nf
ercia
orm
WARNING
m
atio
om
n in
or c
thi
e
torque
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Engine block
❑ Remove and install
crankshaft
⇒ page 47 .
❑ Remove and install pis‐
tons and connecting
rods ⇒ page 50 .
2 - 50 Nm
❑ Tightening sequence:
first tighten the upper
right screw, then the
lower right screw, and fi‐
nally the left screw (front
view, in the direction the agen
AG. Volkswagen AG d
oes
vehicle moves). olksw not
yV gu b ara
ed
3 - Oil filter ris nte
utho e or
❑ Release ⇒ page ss 94 .
a ac
ce
le
❑ Hand tighten.
un
pt
an
d
❑ Follow the oil filter instal‐

itte
y li
erm
lation instructions.
ab
ility
ot p
4 - Bolt
wit
is n
h re
❑ M8 = 20 Nm + 90° (re‐
ole,
spec
place)
❑ M10 = 45 Nm
t to the co
5 - 10 Nm + 90°
rrectne
moval.
❑ Loosen fastening
ss o
screws from the engine
cial p
f i
block crankcase, on the
nform
pulley side (4 units),

mer
atio
from inner side of the

om
crankcase.
n
c
i
or
n thi
e
6 - Crankcase
t
sd
iva
o
pr
❑ Two parts.
um
r
fo
en
ng
❑ Clean sealing surfaces before installation.

t.
yi Co
op py
❑ Install with Silicone sealant for engines - D 176 404 A2 ou A3- . t. C rig
gh ht
yri by
❑ To remove and install, remove oil pan from crankcase. cop Vo
by lksw
cted agen
❑ Removal and installation ⇒ page 92 . Prote AG.
7 - Oil draining plug, 30 Nm

❑ With integrated sealing ring.
❑ Replace.
8 - Compact support
❑ For Generator (Alternator) - - , air conditioning compressor, power steering oil pump and Poly-V belt
fastening element.
❑ Remove and install compact support in vehicles with air conditioning ⇒ Heating - ventilation; Rep. gr.
87 ; Air conditioning
9 - Tensor pulley
❑ For Poly-V belt.
❑ Not applied to the (elastic) Poly-V belt.
❑ For vehicles with air conditioning only.
❑ To loosen Poly-V belt, turn with 16-mm wrench.

10 - Mounting bracket
❑ For snap-in connectors.
11 - 40 Nm
1.1 Seal lid - replace
1.1.1 Removal
– Removal must be executed with a screwdriver after boring with
a chisel.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
1.1.2 Installation
erm
ab
ility
ot p
– Installation must be carried out with a driftpin in the cover di‐
wit
, is n
ameter and depth must be kept at the bevel height. Upon
h re
hole
installation, apply adhesive ⇒ Chemicals Manual .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
1.2 Poly-V belt - remove and install

or
thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
♦ 16-mm wrench
t.
yi Co
Cop py
♦ Compressor - 3297- or Lever - VW 5329/7-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Torque wrench - 5 to 50 Nm ( 1/2” drive)

en AG. V
olks-wVAG
agen A1331-
G
wag does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.2.1 Removal
rrectness of i
Vehicles with air conditioning
l purpos
– Remove lower noise insulation from engine compartment.

– Mark the Poly-V belt running direction.
nform
ercia
– Turn the belt tensioning towards -arrow-, with the 16-mm

m
a
com
t
wrench and remove timing belt.
ion in
r
te o
Vehicles without power steering and air conditioning
thi
s
iva
do
r

rp
cum
fo
en
g
– Mark the Poly-V belt running direction.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen the fastening screws -1- and -2- of the Alternator - - ,

at least by one turn.
– Place the Lever - 3297- or Compressor - VW 5329/7- and lock

it as per -arrow-, with a pulling wire, move the Generator - C-
towards the -arrow- and remove the belt.

1.2.2 Installation
Note
♦ Before installing the Poly-V belt, make sure all aggregates

( Alternator - C- , air conditioner compressor) are properly in‐
stalled.
♦ While installing the Poly-V belt, observe the proper moving di‐
n AG. Volkswagen A
rection and seating of the belt on pulley.
olks
wage
G do
es n
ot g
yV ua
db ran
ise
Vehicles with air conditioningthor tee
or
u ac
sa
– First, place the Poly-Vsbelt on the crankshaft pulley. Then,
ce
e
place the belt on the tensioning element.

nl
pt
du
an
itte
y li
Installation is performed in the reverse sequence to the removal.
erm
ab
ility
ot p
When the job is finished, always:
wit
, is n
h re
– Start the engine and check the belt motion.
hole
spec
Vehicles without power steering and air conditioning
es, in part or in w
t to the co
– Press the Generator (Alternator) - C- up to the tensioning
spring stop with the Lever - 3297- or Compressor - VW 5329/7-
at least three times, to ensure optimized rotation.
rrectness of i
– Next, press the Generator (Alternator) - C- with the Lever -
l purpos
3297- or Compressor - VW 5329/7- against the belt tensioner

until the Poly-V belt can be installed on the pulley.
nf
ercia
– After placing the Poly-V belt, turn the engine several times with
orm
the Generator (Alternator) - C- still loose (approx. 11 revs.). To
m
atio
m
do this, briefly run the starter - B...- .

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
yi
When tightening the Generator (Alternator) - C- bolts, observe the
Co
op py
tightening sequence and do not touch the Poly-V belt. t. C rig
gh ht
pyri by
Vo
co lksw
by
– First tighten the fastening screw -2- to 25 Nm, then the fas‐
cted agen
Prote AG.
tening screw -1- to 25 Nm.
After completing the works:
– Start the engine and check the belt motion.

1.2.3 Poly-V belt - routing

Belt (vehicles with air conditioning and power steering) - routing
1- Power steering oil pump pulley
2- Idler roller
3- Generator (Alternator) - C- pulley
4- Air conditioning compressor pulley
5- Crankshaft pulley
AG. Volkswagen AG d
6- Tensor pulley agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Belt (vehicles without air conditioning and with power steering) -
ce
e
nl
pt
du
routing
an
itte
y li
erm
ab
ility
ot p
2- Tensor pulley
wit
, is n
h re
hole
spec
es, in part or in w
4- Poly-V belt
t to the co
5- Power steering pump pulley
rrectness of i
l purpos
Belt (vehicles without air conditioning and power steering) - rout‐
nf
ercia
ing
orm
m
atio
om
n in
or c
2- Poly-V belt
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Belt (vehicles with air conditioning and power steering) - routing

1- Power steering oil pump pulley.
3- Idler roller.
4- Air conditioning compressor pulley.
5- Crankshaft pulley.

1.3 Poly-V belt (elastic) - remove and install
WARNING
Replace the elastic Poly-V belt with useful life equal to or more
than 60,000 km only with jobs that involve its removal.

♦ Assembly tool - 3277 A- or Assembly tool - T10029- n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Spark plug wrench - 3122B-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
♦ Puller - T02009A- p by
co Vo
by lksw
cted agen
Prote AG.

♦ Assembly tool and Hook
Note
♦ The belt installing tools will be supplied together with the re‐
spective replacement belts.
. Volkswage
♦ For the larger belts,
ksw
athe
gen Aassembly
G
tool, and,
n AG d
oes in addition for the
smaller beltsby(airV conditioning compressor), the
ol n ot g hook.
ua
e d ran
is
♦ Upon ubelt
thor
removal, do not forget to mark the operation
tee
or direc‐
tion,sswhich must be followed upon installation.
a ac
ce
e
nl
pt
du
Poly-V belt (elastic) for the Generator (Alternator) - C- and power

an
itte
y li
steering oil pump

erm
ab
ility
ot p
1.3.1 Removal
wit
, is n
h re
– Remove the Spark plug connectors - P...- with the Assembly

hole
spec
tool - 3277 A- or Assembly tool - T10029- .

es, in part or in w
t to the co
– Remove Spark plugs - Q- with the Spark plug wrench -

3122B- .
rrectness of i
– Remove right front wheel housing protector: ⇒ General outer

body repairs; Rep. gr. 66 ; External equipment .
l purpos
– Install the Puller - T02009/2A- between the Poly-V belt and the
crankshaft pulley.
nform
ercia
– Slowly turn the crankshaft clockwise until the Puller -

m
at
T02009/2A- begins displacing the belt.

om
ion
c
in t
r
– Remove the belt together with the Puller - T02009/2A- .

o
his
ate
do
riv
Air conditioning compressor Poly-V belt (elastic)

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Install the Puller - T02009/1A- between the Poly-V belt and the
air conditioning compressor pulley.
– Slowly turn the crankshaft clockwise until the belt is displaced
together with the Puller - T02009/1A- .
– Mark the belt running direction. lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
1.3.2 Installation
h re
hole
spec
Air conditioning compressor Poly-V belt (elastic)
es, in part or in w
t to the co
– Install the Poly-V belt (elastic), in its correct working position,
on the air conditioning compressor pulley and on the crank‐
shaft pulley, together with Assembly tool -A-.
rrectness of i
– Install Hook -B- in the upper section of the Poly-V belt.
l purpos
– Slowly turn the crankshaft clockwise until the Poly-V belt is

completely installed.
nform
ercia
– Remove the Assembly tool and the Hook .

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Install Hook -a- in the lower section of the Poly-V belt.
AG.

– Take care that the Poly-V belt is perfectly installed both on the
crankshaft pulley and on the air conditioning compressor pul‐
ley.
– Remove Hook -a-from the lower section of the Poly-V belt.
Poly-V belt (elastic) for the Generator (Alternator) - C- and power
steering oil pump

– Install the Poly-V belt on the Generator (Alternator) - C- , power

steering oil pump, return and crankshaft pulleys, together with
Assembly tool -a-.
– Make sure that the Poly-V belt is perfectly installed on the
crankshaft, Generator (Alternator) - C- and power steering oil
pump.
– Install the right front wheel case cover ⇒ General outer body
repairs; Rep. gr. 66 ; External equipment .
– Install the Spark plugs - Q- with Spark plug wrench - 3122B- .
– Install the Spark plug connectors - P...- with the Assembly tool
- 3277 A- or Assembly tool - T10029- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Crankshaft and flywheel flanges - as‐

sembly overview
Note
Clutch repairs: ⇒ Clutch and gearbox; Rep. gr. 30 ; Clutch -

command system .
WARNING

torque
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
1 - 10 Nm hor eo
aut ra
s c
2 - Oil suction tube s
ce
e
nl
pt
❑ For the metallic tube,
du
an
itte
the sealing joint must be
y li
erm
ab
replaced upon removal
ility
ot p
and installation.
wit
, is n
❑ For the plastic tube, the
h re
hole
sealing ring does not
spec
need to be replaced
es, in part or in w
t to the co
upon removal and in‐
stallation.
3 - Engine block
rrectness of i
❑ Crankshaft: remove and
l purpos
install ⇒ page 47 .
❑ Piston and connecting
nform
ercia
rod: remove and install

⇒ page 50 .
m
at
om
io
4 - Knock sensor 1 - G61-
n
c
in t
or
his
e
5 - 20 Nm
at
do
riv
❑ Tightening the torque in‐

p
cum
or
fluences the operation

f
en
ng
t.
yi
of the Knock Sensor 1 -
Co
op py
G61- . t. C rig
gh ht
pyri by
6 - 60 Nm + 90°
o Vo
by c lksw
cted agen
Prote
AG.
moval.
7 - Flywheel
❑ For removal and instal‐
lation of the flywheel,
immobilize it with the
Lock - 3067- .
8 - Intermediate plate
❑ It must be seated on the
coupling guides.
❑ Do not damage/bend during installation.
9 - 6 Nm + 40°

10 - Crankshaft flange with Engine speed sender - G28- rotor and oil seal (flywheel side)
❑ Always replace completely with Engine speed sender - G28- rotor and oil seal.
❑ Use the support sleeve supplied for installation.
❑ To remove and install, remove oil pan.
❑ Do not lubricate nor apply oil on the sealing lip of sealing ring.
❑ Before installation, remove oil residues from crankshaft trunnion with a clean cloth.
❑ The support sleeve will only be able to be removed after moving the flange over the crankshaft trunnion.
❑ Removal and installation of the flange ⇒ page 36 .
11 - Crankshaft flange/oil pump (pulley side)
❑ Replace complete only.
❑ It must be seated on the guide pins.
❑ Carefully observe crankshaft trunnion during installation ⇒ Item 14 (page 33) .
❑ Removal and installation of the oil pump ⇒ page 96 .
12 - Crankshaft seal (pulley side)
❑ Replace ⇒ page 34 .
13 - Sealing gasket
❑ Replace.
14 - Crankshaft trunnion
❑ Apply oil before installing the oil pump.AG. Volkswagen
n AG do
wage es n
Volks ot g
by ua
ed ran
ris tee
2.1 Flywheel - remove and install au
tho
or
ac
ss
ce
e
nl
pt
du
an
♦ Immobiliser - 3067-
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
Removal
m
atio
om
n in
• Gearbox removed.
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Crankshaft and flywheel flanges - assembly overview 33

– Install the Lock - 3067- in the cylinder block; position -B-.

– Remove the fastening bolts from the flywheel.
– Remove flywheel. agen
AG. Volkswagen AG d
oes
olksw not
V gu
Installation d by ara
rise nte
o eo
Installation is aperformed
ut
h
in reverse to removal sequence, consid‐ ra
ering the following: ss c
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
♦ Replace the fastening bolts submitted to angular torque.
, is n
h re
hole
♦ The flywheel may only be installed in one position.
spec
es, in part or in w
t to the co
– Install the flywheel and fastening bolts.
– Install the Lock - 3067- in the cylinder block; position -A-.
rrectness of i
– Apply the indicated torque to the flywheel fastening bolts
l purpos
⇒ Item 6 (page 32)
2.2 Crankshaft seal (pulley side) - replace
nform
mercia
a
com
Special tools and workshop tion in

r
te o
thi
equipment required
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Puller - 3240-
♦ Oil seal extractor - 3415-
♦ Assembly sleeve - T10022-
♦ Sleeve - T10022/1-
♦ Spindle - T10022/2-
2.2.1 Removal
– Release the tension pulley and remove the crankshaft timing
belt ⇒ page 59 .
– Remove crankshaft gear. For this purpose, immobilize the
gear with the Wrench - 3415- .
– To guide the seal Extractor - 3240- install the gear fastening
screw to the crankshaft stop.
– Turn the inner part of the Extractor - 3240- twice (approx. 3
mm) from the external part, and lock it with the splined screw.
– Lubricate the threaded head of the Extractor - 3240- , seat and AG. Volkswagen AG d
screw it by applying as much force to the seal as possible. olkswagen oes
no
V t gu
by
– Loosen the splined bolt and turn the inner part against
ris the
ed
ara
nte
crankshaft until the seal is extracted. utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.2.2 Installation
rrectness of i
– Slightly lubricate the seal lip with oil.
– Place the Assembly sleeve - T 10022- onto the crankshaft
l purpos
trunnion and thread in with the Spindle - T 10022/2- up to the

stop.
nform
ercia
– Displace the seal through the guide sleeve.

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Compress the seal with the Sleeve - T10022/1- to the stop.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
– Install the crankshaft gear and immobilize with the Spanner -
ce
e
nl
3415- .
pt
du
an
itte
y li
– Tighten the new bolt to 90 Nm + 90° (the angular torque may
erm
ab
be applied in several steps).
ility
ot p
wit
, is n
Installing the toothed belt and adjusting the distribution times
h re
⇒ page 59 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.3 Crankshaft flange (flywheel side) - re‐
nform
ercia
place
m
at
om
ion
c
in t
r
Note
o
his
ate
do
priv
♦ New flange with sealant with low wear characteristics, instal‐

um
for
led from the 2nd half of December 2011.

en
ng
t.
yi Co
op py
♦ It is interchangeable with the previous flange. t. C rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.
♦ Wrench insert 24 - VAG 1332/11-

♦ Depth calliper - 1/20 - 300 mm - VAS 6082-
♦ Fitter - T10134- or Fitter - T10017K-
♦ Torque wrench - 5 to 50 Nm ( 1/2” drive) - VAG 1331-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
♦ Feeler gauge
h re
hole
spec
♦ Three hexagonal head screws M 6×35 mm

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
♦ Fitting tool - T10134-

y li
erm
ab
ility
ot p
wit
is n
Note h re
ole,
spec
For SABÓ flange, use Fitter - T10017- or Fitter - T10017K- , and
for Freudenberg flange, use Fitter - T10134- . The method is the

t to the co
same for both tools. Location of references on the tool for instal‐
ling the flange with rotor: SABÓ, upper part and Freudenberg,
lower part.
rrectne
2.3.1 Crankshaft flange with Engine speed

ss o
cial p
sensor - G28- rotor (flywheel side) - re‐

inform
move
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
♦ To show work sequences better, they were carried out with the
en
ng
t.
engine removed.
yi Co
Cop py
ht. rig
♦ The work sequences with the engine installed and gearbox rig ht
py by
removed are identical. co Vo
by lksw
cted agen
Prote AG.
Operation sequence
– Remove flywheel.
– Remove intermediate plate.

– Position the camshaft gear to match the mark -arrow A-.

– Place the crankshaft in the cylinder 1 TDC. The marked tooth
on the crankshaft sprocket must match the “2V” mark on the
flange/oil pump -arrow B-.
– Remove the oil sump ⇒ page 92 .
– Remove the Engine speed sensor - G28- -arrow-.

– Loosen flange fastening screws.
Note
AG. Volkswagen AG d
agen oes
lksw not
The flange and rotor are removed together from the dcrankshaft
by Vo gu
ara
with three screws M 6 × 35 mm. orise nte
eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Install the three M 6 × 35 mm screws in the threaded holes of
ot
wit
, is n
the flange -arrows-.
h re
hole
spec
– Turn screws alternately (max. 1/2 turn (180°) per screw), on
es, in part or in w
the flange and remove the flange with the rotor Engine speed
t to the co
sensor - G28- from the crankshaft.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.3.2 Flange with Engine speed sensor - G28-

rotor - install
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
♦ The flange with PTFE sealing ring comes with horissealing lip thrust nte
eo
ring. This thrust ring works as an installation
s aut sleeve and should ra
c
not be removed before installation. s
ce
le
un
pt
♦ The flange and the Engine speed sensor - G28- rotor can no
an
d
itte
y li
longer be separated or turned after being removed from the
rm
ab
spare parts packaging.
pe
ility
ot
wit
, is n
♦ The Engine speed sensor - G28- rotor reaches its installation
h re
position after being secured to the Fitter fastening pin.
hole
spec
♦ The sealing flange and the sealing ring form one unit and can
es, in part or in w
t to the co
only be replaced together with the Engine speed sensor - G28-
rotor.
♦ The installation position of the Fitter is relative to the crank‐
rrectness of i
shaft by means of a guide pin, which is guided through a
l purpos
threaded hole on the crankshaft.
A - hexagonal nut
nform
mercia
B - threaded spindle
a
com
tion in
C - assembly case
r
te o
thi
s
iva
D - Allen screw
do
r
rp
cum
fo
E - guide pin
en
ng
t.
yi Co
op
F - fastening pin C py
ht. rig
rig ht
A - Crankshaft flange with the Engine speed sensor - G28- rotor
py by
co Vo
by lksw
in the Fitter - install Prote
cted AG.
agen
– Install the hex nut -A- to just before the tightening flat surface
-B- of the threaded spindle.
– Fasten the Fitter on the tightening surface -B- of the threaded

part in a vise.
– Press the assembly case -C- downwards, so that it lies on the
hexagonal nut -A- -arrow-.
Note
The inner part of the Fitter and assembly housing must be on the
same plane.
Freudenberg flange

– Remove the safety clip -A- from the new flange.
wage
Sabó and new Freudenberg flange olks es n
ot g
byV ua
d ran
ir se tee
tho
u or
Note ss
a ac
ce
le
un
pt
The Engine speed sensor - G28- rotor cannot be removed from
an
d
itte
the flange or turned.
y li
rm
ab
pe
ility
ot
Fastening hole -B- in sensor -C- must be aligned with mark -A-
wit
, is n
h re
on the flange.
hole
spec
es, in part or in w
t to the co
Freudenberg flange
rrectness of i
Sabó and new Freudenberg flange
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
The fastening hole -A- on the rotor gear -B- shall be in the upper pyri by
Vo
co
centre position of the flange.
by lksw
cted agen
Prote AG.

– Place the flange with the front part on a flat and clean surface.
– Press the sealing lip thrust ring -A- downwards in the direction
of the -arrow- until it lies on the flat surface.
The upper corner of the Engine speed sensor - G28- rotor and
the front corner of the flange must be aligned with each other
-arrows-.
Freudenberg flange
Sabó and new Freudenberg flange

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Place the flange with the front part on the Fitter , in such a way t to the co
that the fastening pin -A- is inserted into the -B- hole of the
Engine speed sensor - G28- rotor.
rrectness of i
Note
l purpos
Make sure the flange is flat in the Fitter .

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Press the sealing lip thrust ring -B- while tightening AG.the
Volksthree
wagen AG
agen does
splined screws -A- against the Fitter surface,Volksw so that the fas‐ not
gu
tening pin can no longer escape from ed bthe hole on the Engine
y ara
nte
speed sensor - G28- rotor. thoris
eo
au ra
c
ss
ce
le
un
Note
pt
an
d
itte
y li
rm
ab
Ensure the Engine speed sensor - G28- rotor remains fastened
pe
ility
to the Fitter during flange installation.
ot
wit
, is n
h re
hole
B - Fitter with flange onto crankshaft - install
spec
es, in part or in w
Conditions
t to the co
• The crankshaft flange must be free of oil and lubricants.
rrectness of i
• The engine is in TDC for cyl. 1.
l purpos
Operation sequence
– Install the hex nut -A- to the end of the threaded part.
nform
ercia
– Press the threaded fuse of the Fitter towards -arrow-until the

m
a
com
ti
hexagonal nut -A- touches the assembly case -C-.
on in
r
te o
thi
– Align the flat side of the assembly housing with the sealing
s
iva
surface on crankcase side of the block.
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install Fitter with Allen screws -A- on the crankshaft flange.
Note
Insert Allen screws -A- by approx. 5 thread fillets in the crankshaft

flange.
– Install two screws M 6 × 35 mm -A- to guide the flange in the

engine block.
C - Fitter in the crankshaft flange - tighten

olkswagen AG
en AG. V
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox ksw
ag 2006 ➤ , SpaceFox
does201 ...
not
Vol
ed by gu
ara
ris nte
utho eo
– Move the assembly housing -A- the manually
ss towards
a ra
c
-arrow- until the sealing lip thrust ring -B- touches the crank‐
ce
e
nl
shaft flange -C-.
pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
The guide pin -D- on the Fitter is inserted into a threaded hole on
hole
spec
the crankshaft during assembly. Thus, the Engine speed sensor
- G28- rotor reaches the definitive assembly position. es, in part or in w
t to the co
– Keep the assembly housing in this position and manually tight‐
rrectness of i
en both Allen screws on the assembly device.
l purpos
– Install the hex nut -E- manually on the threaded part until it lies
on the assembly case -A-.
nform
ercia
D - Engine speed sensor - G28- rotor with the Fitter on the crank‐
shaft flange - install
m
at
om
ion
c
in t
– Tighten the hexagonal nut of the Fitter using the Torque
or
his
e
wrench - 5 to 50 Nm ( 1/2” drive) - VAG 1331- and SW 24 Open

at
do
riv
socket - VAG 1332/11- . Tightening torque: 35 Nm.

p
cum
for
en
ng
t.
yi Co
op py
Note t. C rig
gh ht
pyri by
Vo
co
After tightening the hex nut with 35 Nm of torque, there should
by lksw
cted agen
Prote
still be a small clearance between the engine block and flange.
AG.
E ⇒ page 46 - installation position of the Engine speed sensor

- G28- rotor on the crankshaft - check
– Install the hex nut -A- to the end of the threaded part.
– Install both screws M6×35 mm -B- on the engine block.
– Loosen the three splined screws -C- from the flange.
– Remove the fitter.
– Remove the sealing lip thrust ring.
The Engine speed sender - G28- rotor is in the exact assembly

position on the crankshaft when there is a distance -A- of 0.5 mm
between the Engine speed sender - G28- -B- rotor and the trunn‐
ion -A-.

– Place the Vernier calliper stem or a steel ruler against the

crankshaft flange -A- (splined surface).
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– By using a feeler gauge -A-, measure the distance -a- between
h re
ole,
the Vernier calliper stem and the Engine speed sensor - G28-
spec
rotor or Depth calliper - 1/20 - 300 mm - VAS 6082- .
t to the co
If distance -a- is too small:
– Press the Engine speed sender - G28-
rrectne
.
If the distance -a- is correct:
ss o
– Remove the fitter.
cial p
f inform
– Screw the flange attaching screws alternately in a cross pat‐
mer
tern. Tightening torque: 10 Nm.
atio
om
n
c
i
or
n thi
– Install the Engine speed sensor - G28- - arrow-. Tightening
te
sd
a
torque: 4.5 Nm.

iv
o
pr
cum
r
fo
– Install the oil pan ⇒ page 92 .
en
ng
t.
yi Co
op
– Install intermediate plate.
C py
t. rig
gh ht
yri by
– Install flywheel using new screws.
op Vo
by c lksw
cted agen
Prote
⇒ page 45 F - Further compress the Engine speed sensor - G28-
AG.
– Move the assembly housing -A- manually in the direction of

the flange-B-.
– Install two screws M6×35 mm -A- to guide the flange-B- in the
engine block.
– Install hex nut -D- manually on the threaded part until it lies on
the assembly housing -A-.

. Volkswagen AG
wa gen AG d
– Tighten the hexagonal nut of theVFitter
olks using the Torque
oes
not
gu
wrench - 5 to 50 Nm ( 1/2” drive)
ed by- VAG 1331- and SW 24 Open ara
nte
socket - VAG 1332/11- . tTightening
horis torque: 40 Nm. eo
au ra
– Check again the assembly
ss position of the Engine speed sen‐ c
ce
e
sor - G28- rotor on the crankshaft
nl
pt
du
.
an
itte
y li
erm
ab
If the distance -a- is again to small:
ility
ot p
wit
– Tighten the hex nut of the fitter with 45 Nm of torque once
, is n
h re
more.
hole
spec
– Check again the assembly position of the Engine speed sen‐
es, in part or in w
t to the co
sor - G28- rotor on the crankshaft.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Crankshaft - remove and install
Note
♦ To perform assembly works, fasten the engine on the assem‐

bly stand, using the Support for VW 643 or VW 643/1 - VW
313- or Rotary stand for engine and gearbox - VAS 6095- .
WARNING

torque
1 - Dragging element
❑ To activate the oil pump.
❑ Apply oil before instal‐
ling the oil pump.
2 - Bearing shells 1, 2, 3, 4 and
5
❑ Spare parts ordering
classification
⇒ page 48 .
❑ For bearing cap without
lubrication groove. n AG. Volkswagen AG do
swage es n
❑ For engine block, with byV
olk ot g
ua
lubrication groove. ir se
d ran
tee
ho
❑ Do not mix the bearing aut or
ac
shells when reusing ss
ce
le
them (mark them).

un
pt
an
d
itte
y li
3 - 65 Nm
rm
ab
pe
ility
ot
moval.
wit
, is n
h re
hole
4 - Bearing cap
spec
es, in part or in w
❑ Bearing cap 1: Pulley

t to the co
side.
❑ Bearing cap 3: With
notches for adjustment
rrectness of i
rings.
l purpos
❑ Cylinder block bearing

caps/bearing cap retain‐
ers must be opposite
nform
ercia
each other.
m
a
com
5 - Bearing shell 3
ion in
r
❑ ⇒ Item 2 (page 47) .

te o
thi
s
iva
❑ Do not mix the bearing

do
r
rp
shells when reusing

um
fo
them (mark).
en
ng
t.
yi Co
op py
6 - Crankshaft t. C rig
gh ht
yri by
❑ New axial clearance: 0.070...00.010 in wear limit: 0.263 mm. cop Vo
by lksw
cted agen
❑ Measure radial clearance with new Plastigage: 0.016...0.036 mm wear limit: 0.070 mm. Prote AG.
❑ Do not turn the crankshaft while measuring radial clearance.
3. Crankshaft - remove and install 47

❑ Crankshaft dimensions ⇒ page 48 .
7 - Fitted ring
❑ For engine block, bearing 3.
8 - Engine block
❑ Check cylinder diameters ⇒ page 53
❑ Piston and cylinder dimensions ⇒ page 53 .
3.1 Identifying engine bearing shells

– Crankshaft bearing shells are classified at the plant and
marked on the engine block and crankshaft as indicated. To
identify the bearing shells, the crankcase must be removed so
that the coloured code can be read.
3.1.1 Crankshaft upper bearing shell code
Note
♦ The engravings may also be grouped around the letter D of

the above illustration.
♦ Use the yellow bearing shells (colour code G) when there is
no identification.
AG. Volkswagen AG d
agen oes
olksw not
A = Code
d by V for bearing 1 gu
ara
ise nte
B = uthor
Code for bearing 2 eo
a ra
C = ss Code for bearing 3 c
ce
e
nl
D = Code for bearing 4

pt
du
an
itte
y li
E = Code for bearing 5

erm
ab
ility
ot p
wit
, is n
3.1.2 Crankshaft bottom bearing shell code

h re
hole
(bearing cap)
spec
es, in part or in w
t to the co
Note
rrectness of i
It may be also engraved on the supporting face of the flywheel.

l purpos
A = Code for bearing 1

nform
ercia
B = Code for bearing 2

m
at
C = Code for bearing 3

om
ion
c
in t
D = Code for bearing 4

or
his
ate
E = Code for bearing 5

do
priv
cum
for
en
ng
t.
3.2 Colour codes
yi Co
Cop py
t. rig
gh ht
yri
R = red
p by
co Vo
by lksw
cted agen
G = yellow
Prote AG.
B = blue
3.3 Crankshaft - dimensions

(dimensions in mm)

Grinding meas‐ Crankshaft bearing Connecting rod

urements Journal-∅ bearing
Crankpin-∅
Basic measure‐ -0.022 -0.022
ment 54.00 47.80
-0.037 -0.037
First grinding -0.022 -0.022
53.75 47.55
-0.037 -0.037
Second grinding -0.022 -0.022
53.50 47.30
-0.037 -0.037
Third grinding -0.022 -0.022
53.25 47.05
-0.037 -0.037
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Crankshaft - remove and install 49

4 Pistons and connecting rods - remov‐

al and installation
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
Lubricate supporting and sliding surfaces prior to installation.
rise
d ara
nte
tho eo
au ra
ss c
ce
le
WARNING
un
pt
an
d
itte
y li
Always replace self-locking nuts and bolts subject to angular erm
ab
ility
torque
ot p
wit
is n
h re
ole,
spec
1 - Piston
t to the co
❑ Check ⇒ page 52
❑ Mark assembly position
rrectne
and correspondence
with the cylinder.
ss
❑ Arrow on piston head
o
cial p
f
points to the pulley side.
inform
❑ Assemble with the pis‐
mer
atio
ton ring tensioning
om
strap.
n
c
i
or
n thi
e
2 - Piston pin
t
sd
iva
o
pr
❑ In case of difficulties
cum
r
fo
during removal, heat
en
ng
t.
yi
piston to 60°C.
Co
Cop py
t. rig
❑ Remove and install with gh ht
yri by
Pin or VW 010-206 - cop Vo
by lksw
cted
10-206- .
agen
Prote AG.
3 - Piston pin retaining ring

❑ Replace.
4 - Connecting rod
❑ Replace complete set
only (4 units).
❑ Mark corresponding po‐
sition relative to cylinder
-A-.
❑ Assembly position:
marks -B- point to the
flywheel side.
❑ On connecting rods
without marks -B-, the
installation position is
the painted faces (con‐
necting rod and cap),
facing the crankcase
venting device side.
❑ Besides defining the pair (connecting rod and cap), colours painted on connecting rods and caps also
define the position (connecting rod in cap).
❑ Piston/connecting ring-to-groove clearance; 0.20...0.40 mm wear limit 0.50 mm.
❑ It is separated from cap by the breakage process ⇒ page 51
5 - Bearing shell
❑ Check assembly position.

olkswagen AG
en AG. V
❑ Do not mix used bearingoshellslksw
ag (mark them). does
not
yV gu
❑ Install bearing shells
ised centrally ⇒ page 53
b ara
nte
or
❑ Measure radialauclearance
th with new Plastigage: 0.020...0.061 emm or wear limit: 0.091 mm. Do not rotate
ac
crankshaft while
ss measuring radial clearance.
ce
le
un
pt
6 - Engine block
an
d
itte
y li
❑ Check cylinder diameter ⇒ page 53
rm
ab
pe
ility
❑ Piston and cylinder dimensions ⇒ page 53 .
ot
wit
, is n
7 - Connecting rod cap
h re
hole
spec
es, in part or in w
❑ Due to the rupture process applied to the connecting rods, the cap can be assembled in only one position
t to the co
and only on the respective connecting rod.
❑ Besides defining the pair (cap and connecting rod), colours painted on caps and connecting rods also
rrectness of i
define the position (cap in connecting rod).
❑ It is separated from body by the breakage process ⇒ page 51
l purpos
8 - Connecting rod screw, 30 Nm + 90°
nform
ercia

m
❑ Lubricate threads and stop surfaces.
a
com
tion in
❑ Tighten to 30 Nm to measure radial clearance, but do not apply the angular torque.
r
te o
thi
9 - Oil scraper rings
s
iva
do
r
rp
c
❑ Remove and install manually and carefully the 3-part oil scraper rings.
um
fo
en
ng
❑ “TOP” mark must point towards piston head.

t.
yi Co
Cop py
❑ Check opening between ends ⇒ page 52 ht. rig
rig ht
py by
❑ Check ring clearance in the piston groove ⇒ page 52 co Vo
by lksw
cted agen
Prote AG.
10 - Compression rings
❑ Remove and install compression rings with compression ring pliers.
❑ “TOP” mark points to piston bottom.
❑ Check opening between ring ends ⇒ page 52
❑ Check ring clearance in the piston groove ⇒ page 52
Typical connecting rods

-A- Conventional connecting rods (smooth separation surface).
-B- Broken connecting rods (rough separation surface).
4. Pistons and connecting rods - removal and installation 51

Openings of piston ring ends - check

– Insert the ring at right angle from top to the cylinder lower
opening, with a distance of approx. 15 mm to cylinder edge.
Ring Opening between ends
new wear limit
1st compression mm 0.20...0.35
wag e n AG 1.0
. Volkswagen AG do
e
ring yV
olks s no
t gu
db ara
2nd compression mmoris 0.20...0.40
e
1.0 nte
eo
ring au
th ra
ss c
Oil scraper ring mm 0.25...0.75 1.0
ce
e
nl
pt
du
an
itte
y li
Check ring clearance in the piston groove
erm
ab
ility
ot p
Clean ring groove before checking.
wit
, is n
h re
Ring Groove clearance
hole
spec
es, in part or in w
new (with new (with wear limit
t to the co
Mahle pis‐ Federal
ton) Mogul pis‐
ton)
rrectness of i
1st compression m 0.030...0.08 0.040...0.0 0.15
ring m 0 80
l purpos
2nd compression m 0.020...0.06 0.020...0.0 0.15

ring m 0 60
nform
ercia
Oil scraper ring m 0.010...0.15 0.010...0.1 0.20

m
at
om
m 0 50
ion
c
in t
or
his
te
Pistons - check
a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ External micrometer 60...90 mm

lkswage 4 - Cyl. injectionesengine
no (1.6 l) - Edition 09.2017
V o t gu
by ara
ed nte
– Measure to approx. 10 mm from ho lower corner, displaced by
ris
eo
90° in relation to the piston pin
aut axis. Divergence in max. nom‐ ra
ss c
inal measure 0.07 mm. Nominal measure ⇒ page 53 .
ce
le
un
pt
Connecting rod bearing shells: installation
an
d
itte
y li
rm
ab
– -1- Bearing shell with bore for piston pin lubrication groove
pe
ility
-arrow-.
ot
wit
, is n
h re
– -1 and 2- Bearing shell positions on connecting rod and con‐
hole
spec
necting rod cap -a- right and left sides equal.
es, in part or in w
t to the co
– -a- Maximum tolerance = 0.2 mm.
rrectness of i
Note
l purpos
Both for connecting rod and connecting rod cap, bearing shells
provide bores to prevent erroneous installation.
nform
mercia
a
Check cylinder compression
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Precision internal micrometer 50...100 mm
– Measure at three different points, in transversal cross pattern,
-A- and in longitudinal direction -B-, with a distance of 10.0 mm
from upper and lower edges -C-. Maximum nominal tolerance
value. 0.08 mm. Nominal measure ⇒ page 53 .
Note
The cylinder diameter should not be measured while the engine

block is secured to the assembly stand with the Support - VW 540-
or Rotary stand for engine and gearbox - VAS 6095- , because
this can produce wrong measurements.
4.1 Piston and cylinder - dimensions

BAH, BLH, BJA and BPA engines
Grinding Piston-∅11) Piston-∅11) cylinder in‐
measure‐ ternal ∅
ments
Manufacturer Mahle KS Pistols
4. Pistons and connecting rods - removal and installation 53

Grinding Piston-∅11) Piston-∅11) cylinder in‐

measure‐ ternal ∅
ments
Basic meas‐ mm 76.465 76.475 76.51
urement
Grinding I mm 76.715 76.725 76.76
Grinding II mm 76.965 76.975 77.01
Grinding III mm 77.215 77.225 77.26
CCRA and CFZA engine
Grinding meas‐ Piston-∅11) Piston-∅ cylinder in‐
urements ternal ∅
Manufacturer Mahle Federal Mo‐
gul
Basic measure‐ mm 76.465 76.463...76. 76.505...7
ment 477 6.515
Grinding I mm 76.715 76.713...76. 76.755...7
727 6.765
Grinding II mm 76.965 76.963...76. 77.005...7
977 7.015
Grinding III mm 77.215 77.213...77. 77.255...7
227 7.265
11) Dimensional data refers to pistons without lining. Pistons which present lining
at the measuring points can be up to 0.030 mm larger in ∅, depending on the
travelled kilometres.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
54
by lksw
cted agen
Rep. gr.13 - Crankshaft group Prote AG.
15 – Cylinder head, valve gear

1 Cylinder head - assembly overview
Check compression ⇒ page 69 .
Note
♦ When a replacement cylinder head is assembled, it is neces‐

sary to lubricate all contact surfaces between support ele‐
ments and valve seats, before assembling the cylinder head.
♦ The plastic shims included for open valve protection should
only be removed immediately before installing the cylinder
head.
♦ When replacing the cylinder head, all coolant must also be
replaced.
♦ With the cylinder head removed, use the Plate - VW 5541/3-
to fasten the cylinder head and valve support.
WARNING

torque
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head - assembly overview 55

1 - 20 Nm + 90°
moval.
wrench - 3036- .
2 - Camshaft gear
❑ Observe fastening dur‐
ing assembly. AG. Volkswagen AG d
agen oes
❑ Check the installation olksw not
yV gu
position of toothed beltsed b ara
nte
⇒ page 59 . thori
eo
au ra
c
3 - 10 Nm ss
ce
e
nl
❑ Apply Liquid sealant - D
pt
du
an
itte
000 600 A2- .
y li
erm
ab
ility
ot p
cover
wit
, is n
h re
hole
5 - Cylinder head cover
spec
es, in part or in w
❑ Sealing surfaces cannot
t to the co
be ground.
❑ Cover and head form a
pair; therefore, the pair
rrectness of i
engraving is on the ex‐
haust manifold side,
l purpos
close to Hall Sensor -

G40- .
nform
ercia
❑ With integrated cam‐

m
shaft bearings.
at
om
io
❑ Remove any residue of

n
c
in t
or
Sealing compound for

his
ate
engines - AMV 188 001

do
priv
02- or Sealing com‐

um
for
pound for engines - D

en
ng
t.
yi
154 103 A1- .
Co
Cop py
t. rig
❑ Apply Sealant compound for engines - AMV 188 001 02- or Sealant compound for engines - D 154 103
gh ht
yri by
A1- before positioning.
op Vo
by c lksw
cted agen
❑ For assembly, place in vertical position from top with guides in cylinder head holes.
Prote AG.

6 - Engine cylinder head screw
❑ Observe assembly and sequence instructions when loosening and tightening ⇒ page 64 .
7 - Oil deflector
❑ It should be locked.
8 - Oil reservoir lid
❑ Replace sealing when damaged.
9 - Finishing
❑ Replace when damaged.
10 - 6 Nm + 90°
❑ Observe installation and sequence instructions when loosening and tightening ⇒ page 81 .
56 Rep. gr.15 - Cylinder head, valve gear

11 - 10 Nm
❑ For the ignition cables.
13 - Guide pin
14 - Roller rockers n AG. Volkswagen AG do
swage es n
❑ Check the roller bearing. yV
olk ot g
ua
b
ed ran
❑ Lubricate the surface of the roller or bearing with oil.
is tee
th or
❑ For installation, fit the safetyssclip
au to the support element. ac
❑ Supplier “INA” with “030” engraving on the side near the spherical region.
ce
e
nl
pt
du
an
❑ Supplier “GTT” with “S3011” engraving on the side near the spherical region.
itte
y li
erm
ab
❑ Do not mix, as in a single head only parts from the same supplier may be installed.
ility
ot p
wit
15 - Support element
, is n
h re
❑ Do not change the working position.
hole
spec
❑ With valve clearance hydraulic offsetting.
es, in part or in w
t to the co
❑ Lubricate the surface of the roller bearing with oil.
❑ Supplier “INA” with“I” engraving on the bottom of the support element.
rrectness of i
❑ Supplier “GTT” with “GT” engraving on the bottom of the support element.
l purpos
16 - Cylinder head sealing gasket
nform
ercia
❑ Metal gasket.
m
❑ Replace.
at
om
ion
❑ After replacing, replace all coolant.
c
in t
or
his
te
17 - Engine cylinder head

a
do
priv
c
❑ It is not allowed to grind the sealing surface on the camshaft side.
um
for
en
ng
❑ The head and the cover form a pair; therefore, the engraving for the pair is on the exhaust tube side,
t.
yi Co
op
close to Hall Sensor - G40- .
C py
t. rig
gh ht
yri
❑ Check warping ⇒ page 58 p by
co Vo
by lksw
cted
❑ After replacing, replace all coolant.
agen
Prote AG.
❑ Remove and install ⇒ page 64 .

18 - Cooling system pipes
❑ Cooling system hose connection diagram ⇒ page 107 .
19 - 20 Nm
20 - Camshaft
❑ Repair ⇒ page 73 .
21 - Camshaft seal
Seal with spring
❑ Quickly lubricate with oil the sealing ring lip.
Seal without spring
❑ The sealing ring lip does not require lubrication.

Cylinder head - check for warping

Max. permissible bending: 0.05 mm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
1.1 Toothed belt semi-automatic tensioning ris nte
ho eo
ut ra
pulley - check s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
i
Test sequence
on
c
in t
or
– Remove air filter body ⇒ page 168 .

his
ate
do
riv

p
cum
for
en
ng
t.
– Remove the front right wheel case protector: ⇒ General body
yi Co
op
repairs, exterior; Rep. gr. 66 ; External equipment .
C py
t. rig
gh ht
yri by
– Mark the Poly-V belt operating direction and remove it
op Vo
by c lksw
⇒ page 24 .
cted agen
Prote AG.
– Remove the heat deflector from the exhaust manifold.

– Remove the tensioning pulley from the Poly-V belt.
Continued for all vehicles
– Remove crankshaft pulley.
– Remove mechanical distribution lower and upper covers.
– Turn crankshaft twice towards the direction of engine rotation
until it is in the cylinder 1 TDC.

– Memorize the position of the belt tensioning indicator arm

-arrow-. Now press with force with your thumb -arrow-on the
timing belt. The indicator arm should move.
– Release toothed belt.
– Turn the crankshaft twice in the direction that the engine turns.
– Check the position of the indicator arm. It must return to the
original position.
If the indicator does not return to its original position:
– Replace the belt tensioning.
If the belt tensioning roller is in order:
– Install the lower and upper covers of the mechanical distribu‐
tion.
– Install the crankshaft pulley (check the fastening). Tightening
torque: 15 Nm + 40°.
– Install Poly-V belt tensioning element. Tightening torque:
♦ M8 = 23 Nm
♦ M10 = 45 Nm agen
AG. Volkswagen AG d
oes
olksw not
V
Continued for all vehicles ed by gu
ara
ris nte
o
– Install exhaust manifold heat baffle. Tightening
aut
h torque: 10 Nm. eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
While installing the Poly-V belt, carefully observe the proper seat‐
h re
hole
ing of the belt on the pulley.
spec
es, in part or in w
t to the co
– Install the front right wheel case protector: ⇒ General body
rrectness of i
l purpos
– Install air filter housing ⇒ page 168 .
1.2 Toothed belt - remove and install, adjust

nform
mercia
at

om
ion
c
in t
♦ Support bracket - 10-222A-

or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Torque wrench - 5 to 50 Nm (1/2” drive) - VAG 1331-
♦ Torque Wrench - 40 to 200 Nm (1/2” drive) - VAG 1332-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
No illustration:
s aut ra
c
s
♦ Lifting eyelets, replacement part number: Support - 030 103
ce
e
nl
pt
du
390 F- pulley side, and Support - 030 103 390 G- flywheel side.
an
itte
y li
erm
ab
♦ -Hexagon key-
ility
ot p
(Adjust command times)

wit
, is n
h re
hole
1.2.1 Removal
spec
es, in part or in w
t to the co

– Remove the front right wheel case protector: ⇒ General body
rrectness of i
– Mark the position of the direction of the Poly-V belt and remove
l purpos
it ⇒ page 24 .
– Remove the heat deflector from the exhaust manifold.
nform
ercia

m
at
om
ion
– Remove the tensioning pulley from the Poly-V belt.

c
in t
or
his
te

a
do
priv
cum
or
– Remove the mechanical distribution top cover.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove crankshaft pulley.

– Remove lower cover to mechanical distributor.
– Disconnect cooling system lines from the engine cylinder
head.
– Screw lifting eyelets in the place of the cylinder head cooling
system pipes. Tightening torque: 25 Nm.
– Place the Support - 10--222 A- with Claws - 10-222 A/1- or the

Adapter - T02007- as illustrated and support the engine in the
assembly position.
– Remove coolant reservoir (hoses remain connected).
– Secure the engine a little and loosen fastening screws -A-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n

h re
hole
– Loosen fastening screws -B- and also the complete subframe.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


– Remove engine support in the engine block.
– Mark the operation direction of the toothed belt.
– Loosen the belt tightener and remove the toothed belt.
1.2.2 Tensioning element without adjustment

– Press the toothed belt in the direction of the -arrow-, on the
right side.
– With the bearings aligned, install the lock pin (Allen 2.5 mm).
G. Volkswagen nA AG do
wage es n
– Remove the tensioningyelement.
Vol
ks ot g
ua
b
ed ra
– Remove the toothed
tho
ris belt and mark the direction of rotation. ntee o
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.2.3 Installation
Conditions
rrectness of i
• The engine must be warm, at most.

l purpos
• The pistons cannot be in the TDC.

nform
mercia
at
Note
om
ion
c
in t
or
When turning the camshaft, the valves may hit the pistons located
his
ate
do
in the TDC.
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Operation sequence
– Place the camshaft gear onto the mark -arrow A-.
– Adjust the crankshaft in the TDC position of cylinder. 1. The
chamfered tooth on the crankshaft sprocket must match the -
2 V - mark on the flange/oil pump -arrow B-.
– Install the toothed belt. Check operation direction on used tim‐
ing belts.
– Manually tighten the fastening screw of the belt tensioning el‐

ement. The base plate notch -1- must reach over
agen
the
AG.fastening
Volkswagen AG
does
screw -2-. Volksw not
g y ua
db ran
– Stretch the toothed belt by turninghorthe
ise belt tensioning element tee
towards -arrow- until the pointer a -3- reaches the mark on the
ut or
ac
base plate -arrow-. ss
ce
le
un
pt
– Tighten the belt tensioning element fastening screw. Tighten‐
an
d
itte
y li
ing torque: 23 Nm.
erm
ab
ility
ot p
– Turn crankshaft twice in the engine rotation direction until it is
wit
again in cylinder 1 TDC.
is n
h re
ole,
– Then, check again the adjustment of the toothed belt and the
spec
position of the belt tensioning element.
t to the co
1.2.4 Tensioning element without adjustment
rrectne
– Install the toothed belt on the camshaft and the water pump
gear.
ss o
– Install the tensioning element with the lock pin (Allen 2.5 mm)
cial p
f in
installed.
form
mer
– Apply 23 Nm of torque to the fastening screw.

atio
om
n
c
– Install the belt on the crankshaft gear.

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove the lock pin (Allen 2.5 mm) from the tensioning ele‐
ment.
– Turn the crankshaft twice in the direction of engine rotation
until reaching top dead centre for cylinder 1.
– Then, check gear positions again.

– If necessary, repeat adjustment of the toothed belt.

– Install engine right support on the engine block. Tightening
torque: 50 Nm.
– Install the lower cover of the mechanical distribution.
– Install the crankshaft pulley (check the fastening). Tightening
torque: 15 Nm + 40°.
– Install Poly-V belt tensioning pulley. Tightening torque:
♦ M 8:= 23 Nm
♦ M 10 = 45 Nm
– Install exhaust manifold heat baffle. Tightening torque: 10 Nm.
– Install the engine subframe. Tightening torque ⇒ page 16 .
– Install the upper cover of the mechanical distribution.
Note
While installing the Poly-V belt, carefully check the proper seating
of the belt on the pulley.
– Install the front right wheel case protector: ⇒ General body

– Install coolant reservoir.
– Remove lifting eyelet from engine cylinder head. swage
es n
olk ot g
yV
– Install the cooling system piping to the engine cylinder head. ed b ua
ran
ir s
Tightening torque: 25 Nm. tho tee
or
au ac
– Install air filter body ⇒ page 168 ss
ce
e
nl
pt
du
1.3 Cylinder head - remove and install an

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Support device - 10-222A- with Claws - 10-222 A/1- or the
l purpos
Adaptor - T02007-
♦ Pin wrench - 3036-
nform
ercia
♦ Guides - 3450-
m
at
om
io
♦ Support - T10014- or Lock - T10109-

n
c
in t
or
his
e
♦ M11/M12 (enc.1/2") multi-toothed socket wrench - VW 001N-

at
do
riv
or Special long wrench - T10070-

p
cum
for
en
g
♦ Oil trap - VAG 1306-

n
t.
yi Co
op py
. C rig
ht ht
rig by
py Vo
No illustration:
co lksw
by
cted agen
Prote AG.

AG. Volkswagen A
Fox 2004 ➤ , Fox 2010 agen
ksw ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ , SpaceFox 201 ...
G do
es n
Vol ot
4 - Cyl. injection
ed bengine (1.6 l) - Edition 09.2017 guar
y
a
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Lifting eyes replacement part number: Support - 030 103 390

F- on pulley side and Support - 030 103 390 G- on engine
flywheel side.
nform
ercia

m
at
om
ion
c
♦ Standard-type clamp pliers - VW 5162 (VWB) - ou - VAS
in t
or
5024A-
his
ate
do
riv
Initial conditions
p
cum
for
en
ng
t.
• Engine warm, at most.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.1 Removal
Note
In order to perform these tasks, it is necessary to disconnect the

Battery - A- earth wire. To do so, check if the vehicle has a coded
radio. if so, request the respective anti-theft code.
– With the ignition turned off, disconnect the earth wire from the
battery - A- .
– Disconnect cooling system lines from the engine cylinder
head.
– Screw lifting eyelets in the place of the cylinder head cooling
system pipes. Tightening torque: 25 Nm.
– Loosen right front wheel case cover ⇒ General body repairs,
external; Rep. gr. 66 ; External equipment .
– Remove toothed belt ⇒ page 59
– Remove the camshaft gear. In order to loosen the fastening
screw, immobilize the gear with the Counterhold - 3036- .
– Loosen three fastening screws of the back cap.
WARNING

removing hose.

– Disconnect the fuel supply pipes 1 (press the unlock key).

(BAH, BLH and CFZA Engines).
– Disconnect the fuel supply pipes 1 (press the unlock key).

(BJA, BPA and CCRA Engines).
– Loosen Magnetic valve I for activated charcoal filter - N80-
-1- on the intake manifold.
– Close the pipes so as to avoid any dirt from coming into the
supply system.
– Disconnect or loosen the following components:
♦ intake manifold vacuum hose for the brake servo.
♦ the fitting connector for the Ignition transformer - N152- and
the Throttle valve control unit - J338- .
♦ injection valve connectors. AG. Volkswagen AG d
agen oes
olksw not
V gu
♦ Connector for the Engine speed d b sensor - G28- and Intake
y ara
ise nte
manifold pressure sensor -thG71-
or / Air intake temperature sen‐ eo
sor - G42- . ss au ra
c
ce
e
♦ 2-pole connector for the Knock sensor 1 - G61- (intake mani‐

nl
pt
du
an
fold side).
itte
y li
erm
ab
♦ the connector for the Coolant temperature sensor - G62- and

ility
ot p
Oil pressure switch - F1- .

wit
, is n
h re
hole
– Disconnect the 3-pole connector of the Sensor Hall - G40-

spec
-arrow-.
es, in part or in w
t to the co
– Remove the fuel distributor with all its injectors in its entirety
⇒ page 166 .
rrectness of i
– Open and close the coolant tank cap to depressurize the cool‐
ing system once more.
l purpos
– Drain cooling system ⇒ page 110 .

nf
ercia
– Remove the clip on the cooling system thermostat valve body,

orm
which holds the cooling system tube on the pump.

m
atio
om
n in
– Remove the thermostat valve body from the engine cylinder

or c
thi
head.
te
sd
iva
o
r
– Disconnect all connection hoses, cooling system, vacuum and

rp
cu
o
suction hoses from the engine cylinder head.

f
en
ng
t.
yi Co
op
– Disconnect exhaust tube from the exhaust manifold.
C py
t. rig
gh ht
yri by
– Loosen the oil dipstick guide tube from intake manifold. cop Vo
by lksw
cted agen
Prote AG.

– Then, raise the engine a little bit with the aid of device -B- .
Note
Since the lifting eyelet is screwed to the engine cylinder head, an

additional support must be secured to the engine block to support
the engine.
– Screw, as indicated, the Support - T10014- or the Lockn A-G. Volkswagen AG do

T10109- in the water pump area on the cylinder lkswage Tight‐
block. es n
o ot g
yV
ening torque: 20 Nm. ed
b ua
ran
is tee
or
– Slightly raise the engine with the aid aof
ut the device -A- until the
h or
ac
threaded part -B- is relieved. ss
ce
le
un
pt
– Remove threaded part -B-.
an
d
itte
y li
erm
– Remove the protection cover of the oil refill nozzle.
ab
ility
ot p
wit
is n
h re
ole,
spec
– Loosen the engine cylinder head screws in the indicated se‐
t to the co
quence and remove them.
– Raise the engine cylinder head carefully.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
1.3.2 Installation
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.
♦ Remove the new engine cylinder head sealing gasket from the
package immediately before installation only.
♦ Handle the new gasket as carefully as possible. Damage may
cause leaks.
– Put a clean cloth on the cylinder so as to prevent any dirt or

sandpaper residues from getting in between the cylinders and
the pistons.
– Also prevent dirt and sandpaper residues from getting into the
cooling system.
– Carefully clean engine cylinder head and engine block sealing
surfaces. Make sure that no longitudinal scrapes or scratches
are produced in this operation (when using sandpaper, the
grain should never be lower than 100).
– Remove sandpaper residues with a cleaning cloth carefully.
– Place the cylinder 1 piston in TDC and turn the crankshaft
slightly backwards.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
risFox
e 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤n,teeSpaceFox 2006 ➤ , SpaceFox 201 ...
ho
aut
4 - Cyl. injection
or
ac engine (1.6 l) - Edition 09.2017
ss
ce
le
un
– To centralize the engine cylinder head, screw the Guides -
pt
an
d
3450/1- into the external rear holes of engine cylinder head
itte
y li
erm
bolts -arrows-.
ab
ility
ot p
– Place the new cylinder head sealing gasket onto the centering
wit
is n
pins -A-. The inscription (spare part number) must be legible.
h re
ole,
spec
WARNING
t to the co
torque
rrectness
– Fit the engine head and the remaining 8 new head screws
o
cial p
f i
manually.
nform
mer
– Loosen the Guides - 3450- with the Extractor - 3450/3- through
atio
m
the screw holes. To do this, turn the Puller - 3450/3- to the left
o
n
c
until removing the guides.
i
or
n thi
te
sd
a
– Insert the two new head screws and tighten them manually.
iv
o
pr
cum
r
fo
en
ng
– Tighten the engine head screws in the tightening sequence

t.
yi Co
op
indicated in the illustration:
C py
t. rig
gh ht
yri by
– First, tighten all fastening bolts to a tightening torque of 30 Nm. cop Vo
by lksw
cted agen
Prote
– Next, apply a 180° angle torque to the bolts, using a hard
AG.
spanner.
Note
There is no need to retighten the engine head screws after the

repairs.
– Continue installation in the reverse sequence to the removal.
Note
When turning the camshaft, the crankshaft cannot be in TDC.

Risk of damage to the piston head/valves.
Installing the toothed belt and adjusting the command times

⇒ page 59 .
Replenish with new coolant ⇒ page 110 .
– Consult the event memory ⇒ page 182 .
1.4 Compression - check

swage es n
Special tools and workshop byV
olk ot g
ua
equipment required ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Spark plug wrench - 3122B-

♦ Cylinder compression gauge - petrol/ethanol - VAG 1763-
♦ Puller - T10029-
Test conditions
• The engine oil temperature must be at least 30°C.
• Battery - A- voltage must be at least 11.5 volts.
• All electrical components, such as lights and thermal rear win‐
dow, must be turned off.
• If the vehicle is equipped with air conditioning, turn it off.
1.4.1 Checking
– Remove the Spark plugs - Q- with the Spark plug wrench -
3122B- .


-arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
– Disconnect the 4-pole connector from the Ignition transformer
nl
pt
du
- N152- -arrow- .
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove fuse 33 from fuse box.
nform
mercia
at
om
i
Note
on
c
in t
or
his
e
Removing fuse 33 interrupts the power supply to the injectors.

at
do
priv
cum
for
en
– Check compression with the Cylinder compression gauge -
ng
t.
yi Co
petrol/alcohol/diesel - VAG 1763- or Adapter for VAG 1763 - t. Cop py
VAG 1381/12- .
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The test equipment operation is described in the corresponding

equipment operation instructions.
– Request another mechanic to step on the accelerator pedal,

so the throttle valve (butterfly) completely opens when the
starter motor is started.
– Operate the starter motor until there is no more increase in the
pressure of the testing device.
Compression values
Engine prefix BAH, BLH, BJA, BPA and CFZA

Cylinder compression bar 10.0 a 15.0
Wear limit bar 7.0
Maximum compression difference between cylin‐ bar 3.0
ders
Engine prefix CCRA

Cylinder compression bar 16.0 a 19.0

4 - Cyl. injection engine (1.6 l) - Edition 09.2017 en AG. Volkswagen AG
ag does
ksw not
y Vol gu
Engine prefix ed
b araCCRA
nte
oris eo
h
Wear limit au
t
bar 11.0ra
c
ss
Maximum compression difference between cylin‐ bar 3.0
ce
le
un
pt
ders
an
d
itte
y li
erm
ab
ility
ot p
wit
– Install the Spark plugs - Q- with the Spark plugs - 3122B- and
is n
h re
tighten to 30 Nm.
ole,
spec
– Check event memory, eliminate possible present failures and,
t to the co
then, erase event memory ⇒ page 182 .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2 Camshaft - assembly overview
Note
♦ Cylinder heads with cracks between the valve seats or be‐

tween a valve seat and Spark plug - Q- threads may continue
to be used without reducing the useful life, provided that such
cracks are small, at most 0.5 mm wide or when only the first
Spark plug - - threads present cracks.
♦ With the cylinder head removed, use a Plate - VW 5541/3- to
fasten the cylinder head and valve support.
WARNING

torque
1 - Camshaft
❑ Check axial clearance
⇒ page 75 .
⇒ page 81 .
❑ Measure radial clear‐
ance with Plastigage,
wear limit: 0.10 mm.
❑ Eccentricity: max. 0.05
mm.
❑ Code ⇒ page 76 agen
AG. Volkswagen AG d
oes
olksw not
V
2 - 6 Nm + 90° ed by gu
ara
ris nte
❑ Replace after every re‐ ut
ho eo
ra
moval. ss a c
ce
e
❑ Observe installation and

nl
pt
du
sequence instructions
an
itte
y li
when loosening and

erm
ab
tightening ⇒ page 81 .
ility
ot p
wit
, is n
3 - Cylinder head cover

h re
hole
❑ The thrust surface can‐

spec
not be serviced with the

es, in part or in w
t to the co
engine cylinder head.

❑ With integrated cam‐
shaft bearings.
rrectness of i
❑ Cover and head form a

l purpos
pair; therefore, the pair

engraving is on the ex‐
haust manifold side,
nform
ercia
close to Hall Sensor -

G40- .
m
at
om
io
❑ Remove all sealant res‐

n
c
in t
r
idues.
o
his
ate
❑ Apply Sealant com‐

do
priv
pound for engines -

um
for
en
AMV 188 001 02- or

ng
t.
yi Co
Sealant compound for engines - D 154 103 A1- before positioning. t. Cop py
rig
gh
❑ For installation, place it vertically on the holes of the cylinder head with guide pins.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
73
AG.
2. Camshaft - assembly overview
4 - Camshaft seal
Seal with spring lkswage es n
o ot g
byV ua
d
❑ Quickly lubricate with oil the sealing ring lip. o
ir se
ran
tee
th or
u
Seal without spring ss
a ac
ce
le
❑ The sealing ring lip does not require lubrication.
un
pt
an
d
itte
y li
rm
ab
pe
ility
5 - Roller rockers
ot
wit
, is n
❑ Check free operation of the roller.
h re
❑ Lubricate sliding surface. hole
spec
es, in part or in w
❑ For installation, loosen the safety clamp on the support element.
t to the co
❑ Supplier “INA” with “030” engraving on the side near the spherical region.
❑ Supplier “GTT” with “S3011” engraving on the side near the spherical region.
rrectness of i
l purpos
6 - Support element
❑ Do not change the working position.
nform
ercia
❑ With valve clearance hydraulic offsetting.

m
a
❑ Lubricate sliding surface.
com
tion in
❑ Supplier “INA” with“I” engraving on the bottom of the support element.
r
te o
thi
s
iva
❑ Supplier “GTT” with “GT” engraving on the bottom of the support element.
do
r
rp
cum
fo
en
ng
t.
yi Co
7 - 25 Nm t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
8 - Lifting tackle/anchoring for engine cted agen
Prote AG.
❑ Spare part numbers: Support - 030 103 390 F- (pulley side) Support - 030 103 390 G- (flywheel side).
9 - Engine cylinder head
❑ The thrust surface cannot be serviced with the cover.
❑ The head and the cover form a pair; therefore, the engraving for the pair is on the exhaust tube side,
close to Hall Sensor - G40- .
❑ Grind valve seat ⇒ page 76 .
❑ Grind sealing surface on the engine block side ⇒ page 75
10 - Valves
❑ Do not grind, may be seated only.
❑ Valve dimensions ⇒ page 76
❑ Remove with the Device - 2036- and the Plate - VW 5541/3- .
11 - Valve guide
12 - Valve stem sealant
13 - Valve spring
❑ After installing the head, remove with the Pressing device - 2037- ⇒ page 85 . After removing the head:
Plate - VW 5541/3- .
14 - Spring plate
15 - Keys

Note
AG. Volkswagen AG d
agen oes
olksw not
With cylinder head removed,eduse b the Plate - VW 5541/3- .
y V gu
ara
ris nte
tho eo
u
Sealing surface on thess cylinder
a block side - grinding ra
c
ce
e
Engine cylinder head grinding measurement: -a- = at least 135.6
nl
pt
du
an
mm.
itte
y li
erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
When grinding the surface, valve seats must be ground with the
es, in part or in w
same measure; otherwise, the valves would hit the pistons. Ob‐
t to the co
serve the minimum elevation permitted.
rrectness of i
2.1 Camshaft - check axial clearance
l purpos
nf
ercia
♦ Mounting bracket - VW 387-
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Dial gauge - VAS 6079-
Checking
Measure with support elements and camshaft cover removed.
– Press the camshaft on central bearing -arrow-, and check the
axial clearance by moving the camshaft in the longitudinal di‐
rection.
Wear limit: max. 0.15 mm.
2. Camshaft - assembly overview 75

Camshaft - code
BAH, BJA, BPA, BLH and CFZA engines
Code between intake and exhaust cams in cylinder 1
Cylinder 1 -arrow- 032 AF and 032 AK
CCRA engine
Code between intake and exhaust cams in cylinder 1
Cylinder 1 -arrow- 030 CF and 032 AG
lkswage es n
o ot g
byV ua
d ran
Valve - dimensions o
ir se tee
th or
au ac
ss
ce
e
Note
nl
pt
du
an
itte
y li
erm
It is forbidden to trim the valves. They can only be seated.
ab
ility
ot p
wit
, is n
Dimensions Intake valve Exhaust valve
h re
hole
spec
∅a mm 34.5 28.0
es, in part or in w
t to the co
∅b mm 5.98 5.96
c mm 99.25 99.25
rrectness of i
α ∠° 45 45
l purpos
2.1.1 Distribution times for 1-mm valve clear‐

ance
nf
ercia
orm
m
atio
BAH, BLH, BJA, BPA and CFZA engines
om
n in
c
032 AF and 032 AK camshaft

or
thi
te
sd
iva
Intake valve Exhaust valve

o
r
rp
cu
o
m
f
en
Opens after TDC 13.0° --------

ng
t.
yi Co
op
Closes after BDC 38.0° --------
C py
t. rig
gh ht
yri by
Opens be‐ BDC -------- 49.0°
cop Vo
by lksw
fore cted agen
Prote AG.
Closes be‐ TDC -------- 4.0°
fore
CCRA engine
030 CF and 032 AG Camshaft
Intake valve Exhaust valve
Opens after TDC 9.0° --------
Closes after BDC 34.0° --------
Opens be‐ BDC -------- 33.0°
fore
Closes be‐ TDC -------- 8.0°
fore
2.2 Valve seat - trim


♦ Depth calliper - 1/20 - 300 mm - VAS 6082-
♦ -Valve seat rectifier-
Note
♦ In case of repairs on engines with leaking valves, simply grind‐

ing or replacing the seats and valves is not enough. The valve
guides must also be checked for wear, especially in engines
with high mileage. ⇒ page 85 .
AG. Volkswagen AG d
♦ trim valve seats only until a flawless attack mark is obtained.
olks
wage
n oes
not
Before trimming, it is necessary to calculate maximumd byV allow‐ gu
ara
able dimensions. If allowable dimensions areorexceeded,
ise it is nte
eo
not possible to ensure hydraulic offsetting afunction
ut
h
of the ra
valves, and in this case, the head will need
s to be replaced.
s c
ce
le
un
pt
an
d
2.2.1 Maximum trimming specification admis‐

itte
y li
rm
ab
sible - calculate
pe
ility
ot
wit
, is n
– Install valve and firmly press it against the valve seat.
h re
hole
spec
es, in part or in w
t to the co
Note
If the valve is replaced during repairs, use a new valve to meas‐
rrectness of i
ure.
l purpos
– Measure the distance -a- between valve end and engine head
upper surface.
nform
ercia
– Calculate maximum and minimum grinding measurements of

m
the measured distance.

com
tion in
r
Minimum measurements: Intake valve and exhaust valve 32.1

te o
thi
mm.
s
iva
do
r
rp
cum
Measured distance minus minimum distance = Maximum grinding

fo
en
g
measurement allowed.
n
t.
yi Co
Cop py
.
For example:
ht rig
rig ht
py by
co Vo
by lksw
- Measured distance Prote32.5 mm
cted AG.
agen
Minimum specification: 32.1 mm
= Max. grinding specification allowed12) 0.4 mm
12) The max. grinding measurement allowed is shown in the illustrations to grind
the valve seats as per measurement “b”.

2.2.2 Intake valve seat - mill

a = ∅ 32.9 mm
b = maximum trimming dimensions admissible
c = max. 1.8...2.0 mm
Z = Lower cylinder head edge
α = 45° Valve seat angle
β = 30° Upper correction angle
γ = 60° Lower correction angle
Note
In case of valve seat rings with a narrowing, grinding must not

damage the narrowing.
2.2.3 Exhaust valve seat - mill

a = ∅ 26.6 mm
b = maximum trimming dimensions admissible
c = max. 1.8...2.0 mm
Z = Lower cylinder head edge
α = 45° Valve seat angle
β = 30° Upper correction angle
γ = 60° Lower correction angle
AG. Volkswagen AG d
agen oes
2.3 Camshaft seal - replace by
Volksw not
gu
ara
ed
ris nte
ho eo
aut ra
Note ss c
ce
e
nl
pt
du
an
♦ New PTFE (polytetrafluorethylene) - Teflon seal (without
itte
y li
spring) installed from the 2nd half of December 2011.
erm
ab
ility
ot p
♦ It is interchangeable with the previous one.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
♦ Pin wrench - 3036- utho
or
a ac
ss
♦ Puller - 3240-
ce
le
un
pt
an
♦ Fitting sleeves - 3241-

d
itte
y li
erm
ab
♦ Fitting tool - T10015/3-

ility
ot p
wit
♦ Sleeve - T10022/1-
is n
h re
ole,

spec
t to the co
2.3.1 Removal
– Release the tensioning pulley and remove the toothed belt
rrectne
from the crankshaft sprocket ⇒ page 59 .

– Remove the camshaft gear. To loosen the screw, immobilize
s
the camshaft gear with a Special wrench - 3036- .

s o
cial p
f in
– Remove rear cover from mechanical distributor.

form
mer
– For seal puller guide, install the camshaft gear screw manually
atio
m
up to the stop on the camshaft.

o
n
c
i
or
n thi
e
– Turn the inner part of the Extractor - 3240- twice (approx. 3

t
sd
va
mm) from the external part, and lock it with the splined screw.
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
79
co Vo
by lksw
cted 2. Camshaft - assembly overview
agen
Prote AG.
– Lubricate the extractor threaded head, seat it and screw it ap‐

plying as much force to the seal as possible.
– Loosen the splined screw and turn the inner part against the
camshaft until the seal is extracted.
– Loosen fastening screw used in the camshaft gear.
2.3.2 Installation
Seal with spring
– Quickly lubricate the sealing lip of the seal with oil.
– Install the Fitting sleeves - 3241- on the camshaft trunnion.
– Slide the seal onto the Guide sleeve - 3241/2- .
– Remove the Guide sleeve - 3241/2- .
– Press the seal with the Sleeve - T10022/1- and the Fitter -
T10015/3- screw up to the stop. Insert a washer between the
pressure sleeve and hex screw.
wage
e ks s no
Vol t gu
Seal without spring ed by ara
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
Fox 2004 ➤ , Fox 2010 ➤b,y VFox 2014 ➤ , SpaceFox 2006no➤
ol t gu, SpaceFox 201 ...
d a
orise 4 - Cyl. injection engine (1.6 l) r-anEdition
tee 09.2017
h
aut or
a
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Introduction of the PTFE (polytetrafluorethylene) - Teflon seal.

♦ Characteristics: The seal with radial veins used until now only
has a seal lip -arrow 1-, which is compressed by a spring. The
PTFE seal has a wider sealing surface -arrow 2- and it doesn't
have a spring.
♦ The sealing surface of PTFE seals does not require lubrica‐
tion.
♦ Pass the seal -A- in the Assembly sleeve - T10022- with the
lip facing the narrow part of the sleeve cone.
♦ Then, install the seal -A- in its correct installation position in
the Assembly sleeve - T10022- and place the Pressure sleeve
- T10022/1- with the installation bolt.
♦ Compress the seal with the Pressure sleeve - T10022/1- into
the Assembly sleeve - T10022- with the bolt - T02006- until
the stop of the Pressure sleeve - T10022/1- on the cylinder
head. Insert a washer between the Pressure sleeve -
T10022/1- and hex bolt - T02006- .
♦ Install the camshaft gear and tighten the new screw (utilize the
Special wrench - 3036- ). Tightening torque: 20 Nm + 90°.

Installing the toothed belt and adjusting the command times
⇒ page 59 .
2.4 Camshaft and cylinder head cover - re‐

moval and installation

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
♦ Sealing compound for engines - AMV 188 001 02- or Sealing
um
r
fo
compound for engines - D 154 103 A1- .
en
ng
t.
yi Co
op py
2.4.1 Removal
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
♦ The sealing surfaces on the cylinder head cover and on the

engine cylinder head cannot be worked on.
♦ The camshaft bearings are integrated with the engine cylinder
head and its cover. Before removing the cylinder head cover,
loosen the toothed belt.
♦ When loosening the cylinder head cover, replace the camshaft
seal.
Operation sequence
Note
During the work, disconnect the Battery - A- ground wire. Check

if the vehicle has code radio; if so, request respective anti-theft
code.
– With the ignition switched off, disconnect the Battery - A- earth

wire.
– Release the toothed belt using the removing and installing
procedure for the toothed belt, without removing the engine
and tensioner support ⇒ page 59 .
– Remove the camshaft gear. To loosen the screw, immobilize
the camshaft gear with a Special wrench - 3036- .

– Loosen the three top fastening screws on the rear cover of the
mechanical distribution.
– Loosen the Ignition transformer - N152- screws from the head
cover of the cylinder.
-arrow-.
– Remove the oil filler cap from the head cover of the cylinder,
unslot and remove the protector.
– Loosen the engine cylinder head cover bolts in the indicated

sequence, -Pos. 9 and 10- must be loosened alternately cross‐
wise.
– Carefully remove the cylinder head cover.
. Volkswagen AG
gen AG does
– Carefully remove the camshaft upwards and placeVitolkon
swaa clean not
surface. ed
by gu
ara
nte
is
or eo
– Remove the rockers together with the support
au
th elements and ra
place them on a clean surface. ss c
ce
e
nl
pt
– Make sure the rockers and support elements are not mixed
du
an
itte
up.
y li
erm
ab
ility
ot p
wit
, is n
2.4.2 Installation
h re
hole
spec
Conditions
es, in part or in w
t to the co
• Avoid penetration of dirt and residues of Sealing compound
for engine - AMV 188 001 02- or Sealing compound for engine
- D 154 103 A1- in head.
rrectness of i
• The sealing surfaces must be free of grease and oil.
l purpos
• The cams on cylinder 1 must be facing upwards when instal‐

ling cylinder head cover and camshaft.
nform
ercia
• The pistons cannot be in the TDC.

m
at
om
io
– Eliminate residues of Sealing compound for engine - AMV 188

n
c
in t
or
001 02- or Sealing compound for engines - D 154 103 A1- from
his
ate
the head and the head cover, by using a liquid solvent.

do
priv
cum
or
– Lubricate the sliding surfaces of the camshaft.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote AG.
For rocker arms and support elements we have 2 suppliers “INA”
and “GTT”, which can not be installed on the same cylinder head
⇒ Item 5 (page 74) ⇒ Item 6 (page 74) .
– Install support elements on the engine cylinder head and re‐

spective rockers.

– Make sure the rockers are properly positioned on the valve

ends -1- and that the respective support elements -2- are
properly fitted.
– Carefully install the camshaft on the engine cylinder head
bearings.
– Apply a thin and uniform film of Sealing compound for engines

- AMV 188 001 02- or Sealing compound for engines - D 154
103 A1- on the clean sealing surface of the cylinder head cov‐
er.
Note
Do not apply a thick film of Sealing compound for engines - AMV

188 001 02- or Sealing compound for engines - D 154 103 A1-
otherwise, excess Sealing compound for engines - AMV 188 001 gen AG. Volkswagen AG d
02- or Sealing compound for engines - D 154 103 A1- may pen‐ Vol
ksw
a oes
not
etrate the lubricating grooves or camshaft bearings, causinged bydam‐ gu
ara
age to the engine. thoris nte
e or
au ac
ss
ce
e
nl
– Place the cylinder head cover carefully in the vertical position
pt
du
an
from top with the guides in the engine cylinder head holes
itte
y li
-arrows-.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
♦ The cylinder head must be fit and fastened without interrup‐
t to the co
tions, as the sealing surfaces start to harden as soon as they
touch each other.
rrectness of i
♦ The cylinder head cover screws must be replaced.
l purpos
– First, tighten the bolts in -Pos. 1 and 2- alternately crosswise

nf
ercia
to 6 Nm.
rm
m
atio
m
– Then, tighten the other screws in the indicated sequence with

o
n in
c
6 Nm of torque.
or
thi
te
sd
a
– Conclude by tightening all screws 90° further.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
pyri by
After the cylinder head cover has been installed, the Sealing
co Vo
by lksw
cted
compound for engines - AMV 188 001 02- or Sealing compound
agen
Prote AG.
for engines - D 154 103 A1- must dry for approx. 30 minutes.
– Install the new camshaft seal ⇒ page 78 .

Installing the toothed belt and regulating command times
⇒ page 59 .

2.5 Valve guides - check

♦ Support - VW 387-
♦ Dial gauge - VAS 6079-
Test sequence
– Place a new valve on the guide. The end of the valve should
be aligned with guide. Due to the various valve guide diame‐
ters, it is recommended that only one intake valve be used on
the intake guide and one exhaust
wage
n AGvalve
. Volkswon
agethe
n AGescape
doe guide.
ks s no
Vol t gu
– Measure tilting gap.
ed Wear limit: 0.8 mm.
by ara
is nte
or eo
If the clearance is
au exceeded:
th ra
ss c
– Replace engine cylinder head.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
2.6 Valve stem sealant - replace

t to the co
Note
rrectne
♦ New low wear (brown colour) seal installed from the 2nd half
of December 2011.
ss o
cial p
♦ Its removal and installation procedure is similar to the seal

inform
used up to the present.

mer
atio
♦ It is interchangeable with the previous one.

om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
85
co Vo
by lksw
cted
2. Camshaft - assembly overview
agen
Prote AG.
. Volkswagen AG
gen AG d
Fox 2004 ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox olk2006
swa ➤ , SpaceFox 201oe...
s no
t gu
yV
ise
d b ara
n r tee
ho
ut or
Special tools and workshop ss
a ac
equipment required
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Lever - VW 541/1A-
♦ Compressor - VW 541/5- or Compressor - VW 541/50-
♦ Flexible tube - VW 653/2A (VWB) - ou - VW 653/3-
♦ Device - 2036-
♦ Impact puller - 3364-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
♦ Seal fitter - 3365-
ot p
wit
, is n
2.6.1 Removal
h re
hole
spec
– Remove toothed belt ⇒ page 59 .

es, in part or in w
t to the co
– Remove camshaft ⇒ page 81 .

– Remove the rockers together with the support elements and
rrectness of i
place them on a clean surface.

l purpos
– Make sure the rockers and support elements are not mixed
up.
nform
ercia
– Remove the Spark plugs - Q- .

m
at
– Place the piston of the respective cylinder in the “Lower Dead

om
ion
Centre”position.
c
in t
or
his
te
– Fasten the Device - 2036- to the cylinder head with the screws
a
do
riv
used in the cylinder head cover.

p
cum
for
en
ng
– Screw the Flexible tube - VW 653/2A (VWB) - ou - VW 653/3-

t.
yi Co
op
to the Spark plug - Q- thread. C py
t. rig
gh ht
yri by
– Connect the pressure hose with at least 6-bar compressed air. cop Vo
by lksw
cted agen
Prote
– Remove the valve springs with a Lever - VW 541/1A- and
AG.
Complement for VW 541/1A and 2037 - VW 541/5- or Com‐

pressor - VW 541/50- .
Note
Stuck valve cotters can be loosened by tapping lightly on the Lev‐

er - VW 541/1A- .
– Remove the valve seal with the Impact extractor - 3364- .

2.6.2 Installation
– Install the supplied plastic sleeve -A- into the respective valve
guide. This procedure avoids damage to the new valve seal
-B-.
– Place the new valve seal on the compressor with the Seal fitter
- 3365- .
– Lubricate the sealing lip of the seal and carefully move it on
the valve guide.
Install cylinder head cover.
– Toothed belt, install and adjust ⇒ page 59 .
Continue installation in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen
17 – Lubrication
oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
1 Lubrication system components ss a c
ce
e
nl
pt
du
an
itte
y li
erm
1.1 Lubricating system components - as‐
ab
ility
ot p
sembly overview
wit
, is n
h re
hole
spec
WARNING es, in part or in w
t to the co
torque
rrectness of i
l purpos
1 - Oil pressure switch 0.3...0.6
nform
ercia
bar , 25 Nm - F1-
m
❑ In case of leakage, cut
at
om
io
and replace the sealing
n
c
in t
r
ring.
o
his
ate
❑ Tightening torque: 20 ±
do
priv
c
3 Nm.
um
for
en
g

n
t.
yi Co
Cop py
t.
2 - Guide tube
rig
gh ht
pyri by
Vo
co
3 - Wood screw, 3 Nm
by lksw
cted agen
Prote AG.
❑ Drill maximum speed:
200 rpm.
❑ Fastened to the intake
manifold.
4 - Oil reservoir lid
❑ Replace sealing when
damaged.
5 - Guide tube funnel
❑ Remove to aspirate oil.
6 - Oil dipstick
❑ Oil level should not ex‐
ceed the max. mark !
❑ Marks ⇒ page 91
7 - Camshaft gear
❑ Check installation posi‐
tion of toothed belt
⇒ page 59 .
8 - To intake manifold
9 - Oil filter
❑ Replace (vehicle on the
lift) ⇒ page 94 .
❑ Follow installation instructions printed on the oil filter.
10 - Gasket
❑ Replace.
❑ It must be seated on the guides.
1. Lubrication system components 89

11 - Tensor pulley
❑ Toothed belt - remove and install, adjust ⇒ page 59 .
AG. Volkswagen AG d
12 - 23 Nm agen oes
olksw not
V gu
d by ara
13 - Toothed belt orise nte
th eo
❑ Mark rotation direction sbefore
au removal. ra
c
s
❑ Check for wear.
ce
le
un
pt
an
❑ Do not bend.
d
itte
y li
rm
ab
❑ Remove and install, adjust ⇒ page 59 .
pe
ility
ot
14 - Upper cover to mechanical distributor
wit
, is n
h re
hole
spec
es, in part or in w
16 - Crankshaft pulley
t to the co
❑ Check the fastening during installation.
rrectness of i
l purpos
17 - 90 Nm + 90°
nform
ercia
❑ To loosen and tighten, immobilize the Wrench - 3415- .

m
a
❑ The angular torque can be performed in several stages.
com
tion in
❑ Angular tightening can be measured with a common angle measuring disc, for example, Hazet 6690.
r
te o
thi
s
iva
do
18 - Crankshaft gear
r
rp
cum
fo
❑ Check installation position of toothed belt ⇒ page 59 . en

ng
t.
yi Co
op
19 - 10 Nm C py
t. rig
gh ht
yri
20 - Seal
p by
o Vo
by c lksw
cted
agen
Prote AG.
21 - 6 Nm + 40°
22 - Crankshaft flange/oil pump (pulley side)
❑ Replace complete only.
❑ It must be seated on the adjusting guides.
❑ To remove and install, remove the crankcase.
❑ Carefully observe crankshaft dragging element during installation.
❑ Removal and installation of the oil pump ⇒ page 96 .
23 - Gasket
❑ Replace.
24 - 10 Nm
25 - Oil suction tube
❑ Clean the strainer if necessary.
❑ For the metallic tube, the sealing joint must be replaced upon removal and installation.
❑ For the plastic tube, the sealing ring does not need to be replaced upon removal and installation.
26 - Dragging element
❑ Apply oil before installing the oil pump.
27 - 10 Nm + 90°
❑ Loosen fastening screws from the engine block/crankcase located next to the pulley (4 units) on the inner
side of the crankcase.
90 Rep. gr.17 - Lubrication

28 - 15 Nm
29 - Oil pan
❑ Clean sealing surfaces before installation. AG. Volkswagen AG d
agen oes
olksw not
❑ Install with Silicone sealant d b for engines - D 176 404 A2 ou A3-
y V gu .
ara
ise nte
❑ Removal and installation
ut
hor
⇒ page 92 . eo
ra
sa c
30 - Oil draining plug, 30s Nm
ce
e
nl
pt
❑ With integrated sealing ring.
du
an
itte
y li
❑ Replace.
erm
ab
ility
ot p
31 - Crankcase
wit
, is n
❑ Two parts.
h re
hole
spec
❑ Clean sealing surfaces before installation.
es, in part or in w
❑ Install with Silicone sealant for engines - D 176 404 A2 ou A3- .
t to the co
rrectness of i
32 - 10 Nm + 90°
l purpos
nf
ercia
33 - Oil nozzle and valve
orm
❑ CCRA and CFZA engines only.
m
atio
m
❑ For piston cooling.

o
n in
or c
thi
❑ The entire assembly is tested at the factory for its opening pressure (1.5 to 1.9 bar), and shape and
te
sd
a
direction of its oil jet.

iv
o
r
rp
cu
❑ The ejectors are fastened under pressure on the engine block, in the seating region of the main bearing
o
m
f
en
ng
sleeves.
t.
yi Co
Cop py
❑ If removed, they must be replaced in order to ensure air-tightness of the system.
t. rig
gh ht
pyri by
Vo
o
34 - Seal
c by lksw
cted agen
Prote AG.
❑ Replace.
35 - Crankcase ventilation device
36 - Up to the air filter
Oil dipstick - marks

1 - max. mark
2 - min. marks
a - Region between the upper corner of the engraved region and
the max. mark: do not refill with oil.
b - Oil level in the marked field: May be filled with oil.
c - Region between min. mark and area below the marked region:
Replenish with 0.5 litre of engine oil.
1.2 Engine oil
Note
♦ Oil level should not exceed the Max. marking due to the risk
of damage to the catalytic converter! Marks ⇒ page 91
♦ After filling, check the oil level with the oil dipstick ⇒ page 91

Check oil pressure ⇒ page 100 .

Oil supply capacities
AG. Volkswagen AG d
♦ With a 4.0 litre oil filter lksw
agen oes
not
Vo gu
13) Current values: ⇒ Exhaust gas Test Folder d by ara
ise nte
or eo
h
Engine oil specification: aut ra
c
ss
♦ Use high lubricating capacity oils according to “VW 502 00”
ce
le
un
pt
specification ⇒ Chemicals Manual for vehicles manufactured
an
d
itte
y li
until the 2013 production series (National market).
erm
ab
ility
ot p
♦ Utilize oils with high lubricating capacity as per “VW 502 00”
wit
⇒ Chemicals Manual (export market, except Paraguay). is n
h re
ole,
♦ Use high lubricating capacity oils according to “VW 508
spec
88”specification ⇒ Chemicals Manua l for total flex vehicles
t to the co
manufactured as of the 2014 production series (national mar‐
ket and Paraguay).
1.3 Oil pan- remove and install
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Portable drilling machine with plastic brush

♦ U/J extension and socket, 10 mm - 3220-
♦ Flat spatula
♦ Goggles
♦ Silicone sealant for engines - D 176 404 A2 ou A3-
1.3.1 Removal
– Remove the lower engine noise insulation ⇒ Body – Repair;
Rep. gr. 50 ; Body - front part .
– Disconnect exhaust tube from the exhaust manifold
⇒ page 185 .
– Drain engine oil.

Fox 2004 ➤ , Fox 2010 ➤wa,gFox
en AG2014
. Volks➤ , SpaceFox
wagen AG
does 2006 ➤ , SpaceFox 201 ...
ks not
by Vol
4 - Cyl. injection engine gu (1.6 l) - Edition 09.2017
a
ed ran
oris tee
th or
au ac
ss
Note
ce
e
nl
pt
du
an
itte
Follow the law regarding oil disposal!
y li
erm
ab
ility
ot p
– Remove oil pan.
wit
, is n
h re
– Remove the four internal fastening screws in the crankcase, hole
spec
on the pulley side.
es, in part or in w
t to the co
– Remove both clutch housing coupling screws to crankcase
support.
rrectness of i
– Now loosen the other crankcase fastening screws.
l purpos
– Remove the crankcase. If necessary, loosen crankcase by

tapping slightly with a rubber hammer.
nform
ercia
– Eliminate residues of Engine silicone sealant - D 176 404 A2

ou A3- remaining on the engine block, with a flat spatula.
m
at
om
io
– Eliminate residues of Engine silicone sealant - D 176 404 A2
n
c
in t
r
ou A3- from the crankcase and oil pan with a rotary brush, for
o
his
te
example a plastic brush attached to a portable drill (wear pro‐

a
do
riv
tective goggles).
p
cum
for
en
ng
– Clean the sealing surfaces. They must be free of oil and

t.
yi Co
op
grease. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.3.2 Installation
Note
♦ Observe the use-by date for the Engine silicone sealant - D

176 404 A2 ou A3- .
♦ The crankcase and the oil pan must be installed within 5 mi‐
nutes after applying the Engine silicone sealant - D 176 404
A2 ou A3- .
♦ The crankcase may be easily and safely installed by putting
threaded pins M6 in two points of the engine block flange.
– Cut the pipe injector at the front marking (∅ of injector is ap‐

prox. 3 mm).
– Apply the Engine silicone sealant - D 176 404 A2 ou A3- as
shown, onto clean crankcase sealing surface. The Engine sil‐
icone sealant - D 176 404 A2 ou A3- cord must:
♦ Be 2...3 mm thick.
♦ Run on inside of the area around the screw holes -arrows-.
Note
The cord of Engine silicone sealant - D 176 404 A2 ou A3- may

not be thicker, otherwise the excess Engine silicone sealant - D
176 404 A2 ou A3- may reach the crankcase and obstruct the filter
in the oil suction tube.

– Apply Engine silicone sealant - D 176 404 A2 ou A3- , as il‐

lustrated, onto the crankcase clean sealing surface (the illus‐
tration shows the position of the cord of Engine silicone sealant
- D 176 404 A2 ou A3- on the engine block).
– Install crankcase immediately and slightly tighten all the agen AG. Volkswagen AG do
screws. Vol
ksw es n
ot g
by ua
ed ran
– Tighten the new crankcase screws with 10 Nm.
ho
ris tee
t or
au ac
– Then, tighten all screws 90° further. ss
ce
e
nl
– Tighten crankcase/gearbox screws to 40 Nm.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Apply the Engine silicone sealant - D 176 404 A2 ou A3- as
l purpos
shown, onto clean sealing surface of oil pan. The Engine sili‐
cone sealant - D 176 404 A2 ou A3- cord must:
nform
ercia
♦ Be 2...3 mm thick.
m
at
om
♦ Run on inside of the area around the screw holes -arrows-.
ion
c
in t
or
his
ate
do
riv
Note
p
cum
for
en
ng
The cord of Engine silicone sealant - D 176 404 A2 ou A3- may

t.
yi Co
op
not be thicker, otherwise the excess Engine silicone sealant - D
C py
t. rig
gh
176 404 A2 ou A3- may reach the crankcase and obstruct the filter
ht
pyri by
Vo
in the oil suction tube.
co lksw
by
cted agen
Prote AG.
– Install oil pan immediately and slightly tighten all the screws.
– Then, tighten screws to 15 Nm.
Note
Once the crankcase is installed, the Engine silicone sealant - D

176 404 A2 ou A3- must dry for approximately 30 minutes. After
this period, the oil may be refilled.
1.4 Oil filter - replace
1.4.1 Filter with hex nut - replace


♦ Chain wrench for oil filter - EQ 7115-
– With vehicle raised, install Chain wrench for oil filter - EQ 7115-
according to illustration. Then, move wrench to right towards
-arrow- until you can release it manually.
– Remove the filter with your hand.
– Lubricate sealing ring with clean engine oil.
– Install the filter and apply torque manually.
1.4.2 Filter without hex nut - replace

♦ Oil filter socket (14 faces) - 3417- or Oil filter remover (14
faces) - VW 5005P-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
♦ Socket wrench - T02017A-

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Torque wrench - 5 to 50 Nm (1/2” drive) - VAG 1331-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
– With the vehicle lifted, install the Oil filter socket (14 faces) -
erm
ab
3417- or Oil filter remover (14 faces) - VW 5005P- in the filter.
ility
ot p
wit
is n
– Next, install the Socket wrench - T02017A- along with the ar‐
h re
ole,
ticulated power cable in the Oil filter socket (14 faces) - 3417-
spec
or Oil filter remover (14 faces) - VW 5005P- .
t to the co
– Move the articulated power cable to the right, releasing the
filter.
rrectne
– Remove the filter with your hand.
– Lubricate the new filter's sealing ring with clean engine oil.
ss o
– Manually install the filter.
cial p
f inform
– Next, install the Socket wrench - T02017A- along with the
mer
"Torque wrench - 5 to 50 Nm (1/2” drive)" - VAG 1331- , in the

atio
m
Oil filter wrench (14 faces) - 3417- or Oil filter remover (14
o
n
c
i
or
faces) - VW 5005P- .
thi
te
sd
va
– Move the "Torque wrench - 5 to 50 Nm ( 1/2” drive)" - VAG

i
o
pr
cum
r
1331- , to the left, applying the indicated torque engraved/

fo
en
ng
printed on the oil filter.

t.
yi Co
Cop py
ht. rig
rig ht
py by
Vo
Note
co lksw
by
cted agen
Prote AG.
Follow installation instructions printed on the oil filter.
1.5 Oil pump - remove and install


equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Oil seal extractor - 3415-

♦ U/J extension and socket, 10 mm - 3220-
rrectness of i
♦ Assembly sleeve - T10022-

l purpos
♦ Fitting Device - 3083-

nform
ercia

m
a
com
tio
1.5.1 Removal
n in
r
te o
thi
s
iva
– Release the tensor pulley and remove the toothed belt from
do
r
rp
the crankshaft sprocket ⇒ page 59 .

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place the crankshaft in the cylinder 1 TDC -arrow-: The cham‐

fered tooth on the crankshaft sprocket must match the “2V”
mark on the oil pump.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
– Turn the crankshaft or gear up to TDC, three teeth in counter
ce
e
nl
clockwise direction: On the right side of the gear’s flattened
pt
du
an
itte
tooth -A-, the third tooth -arrow- must align with the TDC mark‐
y li
erm
ab
ing “2V” on the oil pump housing.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
With this adjustment, the crankshaft is in position for oil pump
t to the co
installation. One of the four dragging polygonal cams on the
crankshaft will be on top.
rrectness of i
l purpos
– Remove the crankshaft gear after immobilizing it with a

Wrench - 3415- .
nf
ercia
orm
– Remove timing belt tensioning element.
m
atio
om
n in
c
– Remove the crankcase ⇒ page 92 .

or
thi
te
sd
a
– Remove the oil suction tube ⇒ Item 25 (page 90) .

iv
o
r
rp
cu
o
m
– Remove oil pump.
f
en
ng
t.
yi Co
op
– Remove the sealing gasket. C py
ht. rig
rig ht
– Remove seal residues from the engine block with a flat spat‐
py by
co Vo
by lksw
ula. Prote
cted AG.
agen
– Clean the sealing surfaces, which must be free of grease and

oil.
1.5.2 Installation
Conditions
• One of the four dragging polygonal cams on the crankshaft
should be on top.
Operation sequence

– Position the Allen screw of the Fitting Device - 3083- with an

Assembly sleeve - T10022- on the crankshaft and tighten
manually.
– Place the new sealing gasket onto the guides -A-.
– Put the -arrow A- mark of the oil pump inner rotor in the in‐
stallation position - -arrow B- mark of the oil pump housing n AG. Volkswagen AG do
cover. olks
wage es n
o V t gu
by ara
– Apply oil to the four dragging polygonal cams on the
ris crank‐
ed nte
shaft. au
tho eo
ra
ss c
– Carefully place the oil pump on the four dragging polygonal
ce
e
nl
cams on the crankshaft.
pt
du
an
itte
y li
– If necessary, align the inner rotor by slightly by turning the four
erm
ab
dragging polygonal cams on the crankshaft.
ility
ot p
wit
, is n
– Then carefully move the oil pump over the guides.
h re
hole
spec
– Screw in the oil pump. Tightening torque: 6 Nm + 40°.
es, in part or in w
t to the co
– Remove the Assembly sleeve - T10022- .
– Install the oil suction tube ⇒ Item 25 (page 90) .
rrectness of i
– Install crankcase ⇒ page 92 .
l purpos
Installing the toothed belt and adjusting the distribution times

⇒ page 59 .
nf
ercia
orm
1.6 Oil pressure switch - F1- - remove and
m
atio
om
install
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
♦ 24 mm articulated socket - T40175-
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw not
Removal: by
Vol
gu
ara
ed
ris nte
ho eo
ut
Caution ss a ra
c
ce
le
un
pt
Protect the components below with a cleaning cloth in order to
an
d
itte
prevent damages due to engine oil leaking.
y li
erm
ab
ility
ot p
wit
is n
– Disengage the connector.
h re
ole,
spec
– Remove the Oil pressure switch - F1- from the engine cylinder
head.
t to the co
Installation:
rrectne
– Install the Oil pressure switch - F1- on the engine cylinder head
as quickly as possible and apply a tightening torque of 20 Nm.
s
– Connect the connector.
s o
cial p
f in
– Remove the cleaning cloth from underneath the Oil pressure
form
mer
switch - F1- .
atio
m
1.7 Oil pressure and Oil pressure switch - F1- - check

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
♦ Oil pressure gauge - VAG 1342-

t.
yi Co
Cop py
♦ Test probe or VAG 1527B - EQ 7300- ht. rig
rig ht
py by
co Vo
♦ Auxiliary measurement cable set - VAG 1594A- ou Auxiliary
by lksw
cted agen
Prote
measurement cable set - VAG 1594C-
AG.
Test conditions
• Check that the engine oil level is correct ⇒ page 91
• Engine oil temperature must be at least 80 °C (the Radiator
fan - V7- must have worked once).
Note
Operation and repair test of visual and acoustic oil pressure indi‐
cator ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

Test sequence
– Remove the Oil pressure switch - F1- and install it on the Oil
pressure gauge - VAG 1342- .
– Install the Oil pressure meter - VAG 1342- in place of the Oil
pressure switch - F1- on the engine cylinder head.
– Connect brown cable from the Oil pressure gauge - VAG 1342-
to the ground (-).
– Connect the Oil pressure gauge - VAG 1342- with the Auxiliary
measurement cable set - VAG 1594C- to the (+) positive ter‐
minal of Battery - A- and to the Oil pressure switch - F1- . The
LED shall not light up.
– If the LED does light up, replace the Oil pressure switch - F1- .
If the LED does not light up:
– Operate the engine and increase the speed slowly. With
0.3...0.6-bar pressure, the LED should light up, otherwise, re‐
place Oil pressure switch - F1- .
– Continue to increase engine speed. At 2000 rpm and oil tem‐
perature at 80ºC, the oil pressure should be at least 2.0 bar.
At higher speeds, oil pressure must not exceed 7.0 bar.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
102
cted agen
Prote AG.
Rep. gr.17 - Lubrication
19 – Cooling
1 Cooling system components - re‐
move and install
WARNING

space:
uum) and electric cables mustwabegenrestored
AG. Volkswto
agtheir
en AGoriginal
does
positions. yV
olks not
g b ua
ed ran
♦ Allow easy accesshoto
ris all the moving or hot parts. tee
t or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ The cooling system is under pressure when the engine is hot.
wit
, is n
Thus, it is necessary to reduce the pressure before conducting
h re
hole
repairs.
spec
es, in part or in w
♦ Hose connection are fastened by spring clamps. For repairs,
t to the co
use spring clamps only.
♦ To install spring clamps, we recommend using the Standard-
rrectness of i
type clamp pliers - VW 5162- or Standard-type clamp pliers -
VAS 5024A- or the Clamp pliers - VAG 1921- .
l purpos
♦ The cooling system hoses should be installed without tension

and without coming into contact with other components (ob‐
nform
ercia
serve the marks on the cooling system connection on the

m
hose).
at
om
ion
c
in t
or
Check the cooling system leaks with the Engine cooling system
his
ate
tester - VAG 1274- or Engine cooling system tester - VAG 1274B-

do
priv
and the VAG 1274 adaptor - VAG 1274/8- and the VAG 1274
um
for
adaptor - VAG 1274/9- .

en
ng
t.
yi Co
op py
Cooling system components, body side ⇒ page 103 . t. C rig
gh ht
pyri by
Cooling system components, engine side ⇒ page 105 .
o Vo
by c lksw
cted agen
Prote AG.
Cooling system hoses connection diagram ⇒ page 107 .
Drain and replenish the cooling system ⇒ page 110 .
Coolant preparation instructions: ⇒ page 110 .
1.1 Cooling system components on the body side - assembly overview
1. Cooling system components - remove and install 103

1 - Radiator agen
AG. Volkswagen AG d
oes
lksw not
❑ Remove and install by Vo gu
ara
⇒ page 119 . rised
nte
ho eo
❑ After replacement,
s aut ra
c
change all
s coolant.
ce
le
un
pt
2 - Seal
an
d
itte
y li
❑ Replace.
erm
ab
ility
ot p
3 - Upper hose of the cooling
wit
is n
system
h re
ole,
spec
❑ Fastened to the radiator
with a clip.
t to the co
❑ Make sure it is well fas‐
tened.
rrectne
❑ Cooling system hoses
connection diagram
⇒ page 107 .
ss o
cial p
f
4 - Coolant temperature sen‐
inform
sor - G62-
mer
❑ BLH engine only.
atio
om
n
❑ With the Sensor for the
c
i
or
n thi
coolant temperature in‐
te
sd
a
dicator - G2- .
iv
o
pr
cum
r
❑ For Engine control unit -

fo
en
ng
J623- .
t.
yi Co
Cop py
❑ While removing, first de‐
t. rig
gh ht
yri
pressurize the system. p by
co Vo
by lksw
cted agen
5 - Immobiliser Prote AG.

6 - Air deflector
7 - 5 Nm
8 - Auxiliary fan
❑ In vehicles with air con‐
ditioning system up to March 20, 2006.
9 - Clip
❑ Make sure it is well fastened.
❑ Of the Radiator fan - V7- .
11 - Connector
12 - Radiator fan - V7-
13 - For cooling system thermostat valve body
14 - Coolant reservoir
Check for cooling system leaks using the Engine cooling system tester - VAG 1274- or Engine cooling system
tester - VAG 1274B- with the Adapter for VAG 1274 - VAG 1274/8- .
15 - Cap
Check for cooling system leaks using the Engine cooling system tester - VAG 1274- or Engine cooling system
tester - VAG 1274B- and the Adapter for VAG 1274 - VAG 1274/9- .
❑ Test pressure 1.4...1.6 bar (vehicles without air conditioning).
❑ Test pressure 1.6...1.8 bar (vehicles with air conditioning).
104 Rep. gr.19 - Cooling

❑ For the Radiator fan - V7- connector.
17 - Lower hose of the cooling system
❑ Fastened to the radiator with retaining clip.
18 - Radiator fan thermal switch - F18- , 35 Nm
❑ Of the Radiator fan - V7- .
❑ Not applicable.
❑ For the radiator.
❑ Observe installation position.
❑ Observe various models.
20 - 5 Nm
1.2 Cooling system components on the engine side - assembly overview
1 - Flange
2 - 9 Nm
3 - Seal
❑ Replace.
4 - Thermostatic valve wagen AG. Volkswagen AG doe
ks s no
❑ Check functioning: Vol Heat t gu
d by ara
the valve ori in water. The
se nte
thermal
aut element pin
h eo
ra
should
ss move outwards. c
ce
e
nl
❑ Temperature test:
pt
du
an
Opening start (approx.

itte
y li
84° C) and opening end

erm
ab
ility
(approx. 98° C) cannot

ot p
wit
be performed.
, is n
h re
hole
5 - To the heat exchanger

spec
es, in part or in w
❑ Cooling system hose

t to the co
connection diagram
⇒ page 107 .
rrectness of i
6 - From the coolant tank

l purpos
connection diagram
⇒ page 107 .
nf
ercia
7 - Thermostat valve housing

rm
m
atio
m
8 - From the heat exchanger

o
n in
or c

thi
te
connection diagram
sd
iva
o
r
⇒ page 107 .
rp
cu
o
m
f
en
ng
9 - Cooling system tube

t.
yi Co
op py
t. C rig
gh ht
yri
connection diagram p by
co Vo
⇒ page 107 .
by lksw
cted agen
Prote AG.
10 - Seal
❑ Replace.

olkswagen AG
en AG. V
11 - Engine block water pump housing ksw
ag does
not
y Vol gu
❑ Water pump - remove and ise
dinstall
b ⇒ page 122 . ara
nte
r
ho eo
12 - Clip au
t ra
c
ss
ce
e
nl
pt
du
an
13 - 10 Nm
itte
y li
erm
ab
14 - Coolant temperature sensor - G2-
ility
ot p
wit
❑ Not applicable to BLH engine. Instead of Coolant temperature sender - G62- , there is a plug for the case
, is n
h re
of need to depressurize the system.
hole
spec
❑ With Coolant temperature sender - G62- .
es, in part or in w
t to the co
❑ For Engine control unit - J623- .
❑ If necessary, depressurize the system before removal.
rrectness of i
15 - Sealing plug
l purpos
16 - Clip
nform
ercia

m
at
17 - 6 Nm
om
ion
c
in t
r
o
his
ate
do
riv
19 - For the radiator, below

p
cum
or

f
en
ng
t.
yi Co
op
20 - For radiator, on top C py
t. rig
gh ht
yri
❑ Cooling system hose connection diagram ⇒ page 107 . p by
o Vo
by c lksw
cted agen
Prote AG.
1.2.1 Water pump side
WARNING

torque

1 - Water pump
❑ Replace the gasket if it
is damaged.
❑ Check for smooth turn‐
ing.
⇒ page 122 .
cover
3 - Camshaft gear
❑ Check the fastening
during installation.
❑ Check the installation
position of toothed belt
⇒ page 59 .
4 - 20 Nm + 90°
moval.
wrench - 3036- .
5 - Toothed belt
❑ Mark rotation direction
before removal.
❑ Check for wear.
❑ Do not bend. lkswage es n
Vo ot g
❑ Remove and install, ad‐ ed by ua
ran
just ⇒ page 59 . thoris tee
o
au ra
6 - Upper cover to mechanical
ss c
ce
e
distributor
nl
pt
du
an
itte
7 - 10 Nm
y li
erm
ab
ility

ot p
wit
, is n
9 - 10 Nm
h re
hole
spec
❑ Install with Liquid sealant - D 000 600 A2- .

es, in part or in w
t to the co
10 - 20 Nm
rrectness of i
1.3 Hose connection diagram for cooling

l purpos
system
nform
ercia
BAH, BJA, BPA and BLH engines

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 - Heat exchanger
3 - Lower hose of the cooling
system
4 - Radiator
5 - Upper hose of the cooling
system
6 - Thermostat valve housing
7 - Engine cylinder head / en‐
gine block
8 - Water pump
10 - Intake manifold
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
CCRA and CFZA engines

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2 - Heat exchanger
3 - Lower hose of the cooling
system
4 - Radiator n AG. Volkswagen AG do
lkswage es n
5 - Upper hose of the cooling d byV
o ot g
ua
system o
ir se
ran
tee
th or
u
6 - Thermostat valve housing ss
a ac
ce
le
7 - Engine cylinder head / en‐ un
pt
an
d
gine block
itte
y li
erm
ab
8 - Water pump
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.4 Cooling system - drainage and replenishment

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Refractometer - T10007A-
♦ Oil collector - VAG 1306- or Oil collector - VAS 6208-
♦ Standard-type clamp pliers - VW 5162- or Standard-type
clamp pliers - VAS 5024A- or Clamp pliers - VAG 1921- or
Clamp pliers - VAS 6340-
♦ Cooling system supply unit - VAS 6096-
♦ Adapter for VAG 1274 - VAG 1274/8-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
♦ Engine cooling system tester - VAG 1274- or Engine cooling
t to the co
system tester - VAG 1274B-
1.4.1 Drain rrectness of i

l purpos
WARNING
nf
ercia
Hot vapours may escape when the coolant reservoir is opened;

or
cover it with a cloth and open carefully.

m
m
atio
om
n in
or c
thi
– Open the coolant tank lid.

te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
With draining device
yi Co
Cop py
t. rig
– Open the drainage device on the radiator cooling system gh ht
yri by
-arrow-. cop Vo
by lksw
cted agen
Prote AG.
Without draining device

– Release the lower hose at the radiator (left side) -arrow-.
Note
Follow the recommendations for coolant disposal!
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.4.2 Replenishing
Note
♦ One of the elements that most affect coolant efficiency is the

water used in its preparation. The quality of the water to be
used is based on multiple substances, which may present dif‐
ferent specifications depending on the country or even in
different regions. Fresh water meets all requirements. There‐
fore, the coolant must be prepared with fresh and drinkable
water, either when preparing new filling procedures or cool‐
ants used to top off the coolant tank.
♦ Only the antifreeze additive may be used. Correspondence:
⇒ Electronic Parts Catalogue“ETKA” It is identified by the pink
colour. AG. Volkswagen A gen G do
swa es
♦ Do not mix antifreeze additive
by
Vowith
lk other types of antifreeze
not
gu
additives from other suppliers
ris
ed under any circumstance. ara
nte
ho e
♦ A brown colour in reservoir indicates that the an‐ theaut coolant or
ac
ss
tifreeze additive has been mixed with other antifreeze addi‐
ce
le
tives. In this case, replace all of the coolant.

un
pt
an
d
itte
y li
♦ The antifreeze additive prevents damages caused due to cor‐
erm
ab
rosion, freezing, or slob sedimentation, further increasing the
ility
ot p
coolant's boiling temperature. Therefore, the cooling system
wit
is n
must always have the recommended mixture of antifreeze and
h re
ole,
anti-corrosion products.
spec
♦ Due to the high boiling temperatures it provides, antifreeze is
t to the co
especially helpful in tropical countries, ensuring safe operation
when the engine is submitted to heavy-duty work.
rrectne
♦ Antifreeze protection must be assured to approximately -25 °
C (in countries with Arctic climates, to approximately -35 °C). ss
♦ Coolant concentration must not be diluted by adding fresh and
o
cial p
drinkable water during hot seasons, or in countries with hot

inform
climates. The percentage of antifreeze should be at least 40

mer
%.
atio
om
n
c
♦ If the climate requires greater antifreeze protection, the anti‐

i
or
n thi
freeze additive percentage may be increased, but to a maxi‐

te
sd
a
mum of 60 % (antifreeze protection up to -40 °C). The higher

iv
o
pr
proportion lowers cooling capacity and antifreeze protection.

um
r
fo
en
ng
t.
yi
♦ Use the Refractometer - T10007A- to determine the antifreeze
Co
op py
protection and the corresponding antifreeze protection per‐
t. C rig
gh ht
yri
centage. p by
co Vo
by lksw
cted agen
♦ Do not reuse used coolants, including in situations in which Prote AG.
drainage is required.
♦ Use only clean drinkable water to prepare the coolant.
Recommended proportions:
Antifreeze protec‐ Antifreeze propor‐ Coolant Water14)
tion up to tion additive14)
-25 °C 40 % 2.25 l 3.35 l
-35 °C 50 % 2.8 l 2.8 l
14) The coolant volume may vary according to the equipment on each vehicle.
With draining device

– Close the drainage device of the cooling system -arrow-.

Without draining device
– Fit the lower hose on the radiator (left side) -arrow-.

With the Cooling system supply unit - VAS 6096-
– Remove coolant expansion tank lid.

– Install the Adaptor for VAG 1274 - VAG 1274/8- on the coolant
tank.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
– Install the Cooling system supply unit - VAS 6096- .

un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
A small quantity of coolant is removed along with the air dis‐

hole
spec
charge, which must be collected.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
114
by lksw
cted agen
Rep. gr.19 - Cooling Prote AG.
lkswage es n
o ot g
byV ua
ed ran
Fox 2004hor ➤ , Fox 2010 ➤ , Fox 2014 ➤ , SpaceFox
is tee 2006 ➤ , SpaceFox 201 ...
t or
au 4 - Cyl. injection engine ac (1.6 l) - Edition 09.2017
ss
ce
e
nl
– Close the valves -A- and -B-, allowing levers to seat trans‐
pt
du
an
itte
versely to the passage direction.
y li
erm
ab
– Connect the hose -3- to the compressed air system.
ility
ot p
wit
The compressed air pressure must be 6 to 10 bar. , is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Open the valve -B- placing the lever in the passage direction.
nf
ercia
orm
The aspiration jet pump generates vacuum in the cooling system;
m
atio
m
the instrument gauge must move towards the green area.

o
n in
or c
thi
– Briefly open valve -A- placing the valve in the direction of the
te
sd
a
flow, in order to fill the Cooling system supply unit - VAS 6096-
iv
o
r
rp
cu
coolant reservoir hose with coolant.
o
m
f
en
ng
t.
yi
– Close valve -A-.
Co
Cop py
t. rig
gh
– Leave valve -B- open for more than 2 minutes.
ht
pyri by
Vo
co lksw
by
The aspiration jet pump continues to generate vacuum in the
cted agen
Prote AG.
cooling system; the instrument gauge must stay in the green area.
– Close valve -B-.
The instrument gauge must remain still in the green area; the
vacuum in the cooling system is sufficient to ensure proper sup‐
ply.
Note
♦ If the gauge is below the green area, the operation must be

repeated.
♦ If the vacuum reduces, check the cooling system for exhaust
points.
– Remove the compressed air hose.

– Open the valve -A-.
Due to the vacuum in the cooling system, the coolant is aspirated
from the Cooling system supply unit - VAS 6096- into the cooling
system.
– Remove the Cooling system supply unit - VAS 6096- and the
VAG 1274 adaptor - VAG 1274/8- from the coolant tank.
– Supply the coolant tank until the maximum mark.

– Install the coolant tank cap.

Without the Cooling system supply unit - VAS 6096-

– Supply the coolant tank until reaching the maximum mark.
tank.
– Attach the Connection terminal - V.A.G 1274 B/1- to the VAG
1274B adaptor - VAG 1274/8- . AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Connect the Connection terminal - V.A.G 1274 B/1- to the En‐
pe
ility
gine cooling system analyzer - VAG 1274 B- through the
ot
wit
flexible connection tube.
, is n
h re
hole
– With the Engine cooling system analyzer - VAG 1274B- , gen‐
spec
erate a pressure of approx. 1.5 bar.
es, in part or in w
t to the co
DANGER!
rrectness of i
Risk of burns! Before removing the Engine cooling system an‐
l purpos
alyzer - VAG 1274B- from the VAG 1274 adaptor - VAG

1274/8- and the Connection terminal - V.A.G 1274 B/1- , elim‐
inate all system pressure. Press the pressure relief valve in the
nform
ercia
Engine cooling system analyzer - VAG 1274B- , until the man‐

m
ometer reads »0«.

a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Supply the coolant tank until the upper edge. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Install the coolant tank cap.

– Switch off the air conditioning, if applicable.
– Turn off heating start device.
– Start the engine and keep it idling until it is heated.
– Maintain engine rotation at approx. 3800 rpm, until the Radi‐
ator fan - V7- is activated.
– After the Radiator fan - V7- is activated, maintain engine ro‐
tation at approx. 3800 rpm for an additional 5 minutes.
– Turn the engine off.
WARNING
When opened, hot vapours may come from the coolant tank.
Wear protection goggles and clothing to prevent eye injuries
and burns. Place a cloth on the tank flap and open it carefully.
– Check coolant level and top off if necessary.

• With the engine under normal operating temperature, the cool‐
ant may be at the “max.” mark or above.
• With the cold engine, the coolant level must be between the
“min. mark” and “max. mark”.
1.5 Cooling system - check air-tightness

♦ Engine cooling system tester - VAG 1274- or Engine cooling
system tester - VAG 1274B-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
♦ Adapter for VAG 1274 - VAG 1274/8-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
117
cted agen
Prote AG.
1. Cooling system components - remove and install
♦ Adapter for VAG 1274B - VAG 1274/9-
Checking condition
• Engine under operating temperature.
Checking sequence
WARNING
♦ Hot vapours may escape when the coolant reservoir is

opened; cover it with a cloth and open carefully.
♦ Safety measures must be followed.

tank.
1274B adaptor - VAG 1274/8- .
. Volkswagen AG
– Connect the Connection terminal - V.A.G 1274 B/1- to thekEn‐
swa
gen AG does
gine cooling system analyzer - VAG 1274B- through bthe
y V flex‐
ol not
gu
ara
ible connection tube. ris
ed nte
tho eo
– With the Engine cooling system analyzer - VAG
ss
au 1274B- , gen‐ ra
c
erate a pressure of approx. 1.5 bar.
ce
e
nl
pt
du
an
itte
y li
DANGER!
erm
ab
ility
ot p
wit
Risk of burns! Before removing the Engine cooling system an‐

, is n
h re
alyzer - VAG 1274B- from the VAG 1274 adaptor - VAG

hole
spec
1274/8- and the Connection terminal - V.A.G 1274 B/1- , elim‐

es, in part or in w
inate all system pressure. Press the pressure relief valve in the
t to the co
Engine cooling system analyzer - VAG 1274B- , until the man‐

ometer reads »0«.
rrectness of i
If the pressure does not drop:

l purpos
– Locate and eliminate the exhaust area in the engine compart‐

ment (upper engine part) and on the lower part of the vehicle
nf
ercia
(lower engine part).

rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Coolant tank flap - check safety valve

– Install the coolant tank flap -1- in the VAG 1274B adaptor -
VAG 1274/9- -2-.
1274B adaptor - VAG 1274/9- .
– Connect the Connection terminal - V.A.G 1274 B/1- to the En‐
gine cooling system analyzer - VAG 1274- or Engine cooling
system analyzer - VAG 1274B- through the flexible connection
tube.
– With the manual pump of the Engine cooling system analyzer
- VAG 1274- or Engine cooling system analyzer - VAG
1274B- , generate a pressure of up to 1.6 bar.
With a pressure of 1.6...1.8 bar, the safety valve must be opened.
The safety valve must not open.
If the safety valve opens beyond the specified time limit:
– Replace the coolant tank flap.
– Increase the pressure.
The safety valve must open after exceeding the indicated pres‐
sure.
If the safety valve does not open:
– Replace the coolant tank flap.
1.6 Radiator - remove and install
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
clamp pliers - VAS 5024A- or Clamp pliers - VAG 1921-

1.6.1 Removal
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumpers .
. Volkswagen AG
– Remove the lock carrier ⇒ General body repairs, exterior; wage
n AG does
Rep. gr. 50 ; Body - Front section . Volks not
gu
by ara
ed nte
ris
– Drain cooling system ⇒ page 110 . tho eo
au ra
c
– Loosen quick couplings from the radiator ss
cooling system.
ce
e
nl
pt
du
– Remove the radiator fan connector - V7- . an

itte
y li
erm
– Loosen the radiator fastening screws and remove the radiator ab

ility
ot p
with Radiator fan - V7- . wit

, is n
h re

hole
spec
– Observe additional indications and installation works

es, in part or in w
t to the co
⇒ page 122 .
1.6.2 Installation
rrectness of i
Installation is carried out by inverting the removal sequence, ob‐

l purpos
serving the following:

– Replenish cooling system ⇒ page 110 .
nform
ercia
– Install front end ⇒ General body repairs, exterior; Rep. gr.

m
50 ; Body - Front section .

at
om
ion
c
– Install bumper cover ⇒ General body repairs, exterior; Rep.

in t
or
his
e
gr. 63 ; Bumpers .
at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.6.3 Additional notes and installation works

in vehicles with air conditioning
WARNING
The cooling gas circuit for the air conditioner should not be
opened.
Note
To prevent faults in the cooling gas hoses and condenser, make

sure the hoses are not stretched, bent or crushed.
– Loosen cooling gas hose retaining clamp(s). AG. Volkswagen AG d

agen oes
ksw not
– Loosen radiator condenser and support it. byV
ol
gu
ara
ed
is nte
1.7 Water pump - remove and install or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
equipment required
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

clamp pliers - VAS 5024A- or Clamp pliers - VAG 1921-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos
♦ The integrated seal in the water pump must not be separated
nform
from the pump.
mercia
♦ In case of leaks and faults, replace the sealing. a

com
tion in
r
te o
1.7.1 Removal
thi
s
iva
do
r
rp
– Drain cooling system ⇒ page 110 .

um
fo
en
ng
t.
yi
– Remove toothed belt ⇒ page 59 .
Co
Cop py
t. rig
gh
– Remove the camshaft gear. Loosen the screw, immobilizing
ht
pyri by
Vo
o
the camshaft gear with the Wrench - 3036- .
c by lksw
cted agen
Prote AG.

– Loosen fastening screws -arrows-from the water pump and

mechanical distribution rear cover.
– Remove the water pump together with the engine block me‐
chanical distribution rear cover .
1.7.2 Installation
Installation is carried out by in reverse order of the removal se‐
quence, whilst observing the following:
– Install the water pump with the mechanical distribution rear
cover and tighten the lower fastening bolts. Tightening torque: gen AG. Volkswagen AG d
20 Nm. Vol
ksw
a oes
not
y gu
db ara
– Tighten the three upper fastening bolts on the mechanical
ris
e dis‐ nte
ho eo
tribution rear cover. Tightening torque: 10 Nm (install
aut with ra
Liquid sealant - D 000 600 A2- . ss c
ce
le
un
pt
– Install the camshaft sprocket and tighten the new bolt (use the
an
d
itte
Special wrench - 3036- ). Tightening torque: 20 Nm + 90°.
y li
erm
ab
ility
Installing the toothed belt and regulating command times
ot p
wit
⇒ page 59 .
is n
h re
ole,
Replenish cooling system ⇒ page 110 .
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

20 – Fuel supply system

1 Fuel supply system components - re‐
Note
♦ Hose connections are fitted by spring, pop top clamps, and,

for the latter, always replace the lock when disconnected.
♦ To fasten the fuel hoses to the engine, use spring clamps only.
Using tightening or screwed clamps is not allowed.
♦ To install spring clamps, we recommend using the Standard-
type clamp pliers - VW 5162- or Standard-type clamp pliers -
VAS 5024A- or the Clamp pliers - VAG 1921- .
Follow safety measures ⇒ page 128 .

Follow cleaning rules ⇒ page 129 . lkswage es n
o ot g
byV ua
ed ran
Removal and installation of theorfuel tank ⇒ page 138 .
is tee
th or
u
Fuel tank components withssaccessories and fuel filter - remove
a ac
and install ⇒ page 125 .
ce
le
un
pt
an
d
Repair engine power electronic adjustment parts (electronic ac‐

itte
y li
rm
celerator) ⇒ page 150 .
ab
pe
ility
ot
Repair the activated charcoal filter system components
wit
, is n
⇒ page 152 .
h re
hole
spec
1.1 Fuel tank components with accessories and fuel filter - assembly overview
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Fuel supply system components - removal and installation 125

1 - Fastening clip
2 - Reservoir cap
3 - Seal
❑ Replace if damaged.
4 - Fastening screw
5 - Fuel reservoir lid
❑ With rubber boot.
❑ Remove and install ⇒
General body repairs,
exterior; Rep. gr. 55 ;
Caps
6 - Fuel supply line
7 - Vent valve
❑ ⇒ page 128
8 - Activated charcoal filter
❑ Installation location: in
the right rear wheel
case.
9 - 10 Nm
10 - Spring clamp
11 - Fuel reservoir
❑ Remove using the
Gearbox or engine +
gearbox assembly jack
AG. Volkswagen AG d
or VAG 1383A - EQ ksw
agen oes
not
l
7081- . byV
o gu
ara
ed
❑ Remove and install horis nte
eo
⇒ page 138 . s aut ra
c
s
12 - 25 Nm
ce
e
nl
pt
du
an
itte
13 - Hose from the tank to the
y li
erm
ab
activated charcoal filter
ility
ot p
wit
14 - Hose from the tank to the gravitational valve
, is n
h re
hole
15 - Bearing
spec
es, in part or in w
16 - Gravity valve
❑ For removal, remove the cover of the right rear wheel housing. t to the co
❑ Check valve passage continuity. Perpendicular valve: open. Valve inclined 45°: closed.
rrectness of i
17 - Junction
l purpos
18 - Quick coupling
nf
ercia
19 - Fuel filter
orm
❑ Installation position: the arrow indicates the flow direction.

m
atio
om
❑ Pop Top quick coupling, replace lock when disconnected ⇒ page 129
n in
or c
thi
e
20 - Fuel level indicator sensor - G-

t
sd
iva
o
r
rp
cu

o
m
f
en
ng
t.
21 - Fuel pump (pre-supply pump) - G6-
yi Co
Cop py
❑ Remove and install ⇒ page 135 . ht. rig
rig ht
py by
❑ During pump removal, replace the sealing ring.
co Vo
by lksw
cted agen
Prote
❑ Clean filter, if dirty.
AG.
❑ Check the Fuel pump (pre-supply pump) - G6- ⇒ page 141 .

❑ Check the installation position on the fuel tank ⇒ page 128
126 Rep. gr.20 - Fuel supply system

22 - Supply tubes
❑ Black.
❑ For fuel distributor.
23 - Return pipes
❑ Blue.
❑ Fastened laterally to the fuel reservoir.
24 - Thrust ring
25 - Snap ring
Spacefox/Suran reservoir nozzle
1 - Lock cylinder
2 - Nozzle cover
3 - Nozzle boot
4 - Vent valve
❑ To remove, nudge it
sideways from the fuel
tank nozzle. agen
AG. Volkswagen AG d
oes
lksw not
❑ Before installing, re‐ d by Vo gu
ara
move the fuel tank cov‐ orise nte
er. Refer to auth eo
ra
⇒ page 128 ss c
ce
e
nl
pt
5 - Gravity valve
du
an
itte
y li
❑ To remove, nudge it up‐
erm
ab
wards out of the fuel
ility
ot p
tank nozzle.
wit
, is n
h re
❑ Check valve continuity.
hole
spec
Perpendicular valve:
es, in part or in w
open, Valve inclined t to the co

45°: closed.
6 - 8 Nm
rrectness of i
7 - Fuel filler neck

l purpos
8 - Fuel filter
❑ Assembly position: the
nf
ercia
arrow indicates the flow

orm
direction.
m
atio
m
❑ Relieve fuel pressure in

o
n in
or c
the system prior to re‐

thi
te
moval.
sd
iva
o
r
rp
cu
9 - Fuel reservoir
o
m
f
en
ng
t.
yi Co
10 - Anti-choke hose t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Installation position for the Fuel pump (pre-supply pump) - G6-

The arrow on the Fuel pump (pre-supply pump) - G6- should point
towards the front of the vehicle.
For the SpaceFox/Suran, the -arrow- at the right of return line
(blue pipe) in the pump must match the arrow of the fuel tank
Blue return lines -1- in the connection.
Black supply lines -2- in the connection.
Electrical connector of the Fuel pump (pre-supply pump) - G6-
-3-.
Note
After installing the Fuel pump (pre-supply pump) - G6- , check that
supply and return lines are still fastened to the fuel tank.
Vent valve - check

Lever in the resting position: closed. agen
AG. Volkswagen AG d
oes
olksw not
Lever pushed in the -arrow -direction:by V open. gu
ara
ed
ris nte
ho eo
aut ra
s c
Note s
ce
le
un
pt
an
d
itte
Before vent valve installation, remove fuel reservoir lid.

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
1.2 Safety measures regarding work on the

t to the co
fuel supply systems

rrectne
WARNING
ss o
Remember the following when performing assembly work, es‐

cial p
f in
pecially inside the engine compartment where there is little

form
mer
space:
atio
m

o
n
c
i
or

thi
te

sd
iva
o
r
positions.
p
cum
r
fo
en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
While removing or installing the Fuel gauge sensor - G- or the by c lksw
cted agen
Water pump (pre-supply pump) - G6- , when the fuel reservoir is
Prote AG.
full or partially full, observe the following:
WARNING

removing hose.
♦ Before starting installation work, place the suction hose of a

gas extraction device near the fuel tank opening in order to
extract to absorb gases released by the fuel. If an extracting

device is unavailable, use a radial fan (the engine must be out

of air flow) with rate of air displacement greater than 15 m3/
hour.
♦ Avoid skin contact with fuel! Wear fuel resistant gloves!
♦ For safety reasons, before opening the system, remove fuse
number. 33 of the Fuel pump (pre-supply pump) - G6- .
1.3 Cleaning rules

For cleaning, carefully observe these “5 rules” when working on
the fuel supply/injection system:
♦ Thoroughly clean the connections and surrounding areas be‐
fore disconnecting them.
♦ Place parts on clean surface and cover them. Use lint-free
cloths!
♦ If the repair work will not be performed immediately, exposed
components must be covered or carefully preserved.
♦ Install clean components only. Remove spare parts from pack‐
aging just prior to installation. Do not install components that
have been stored outside of packaging (i.e. inside a tool box,
etc.). en AG. V
olkswagen AG
ag does
lksw not
♦ With the system open: If possible, avoid using compressed
yV
o air. gu
db ara
Do not move vehicle, if possible. orise nte
th eo
au ra
1.4 Quick connection “Pop Top” - discon‐ ss c
ce
e
nection and connection

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Wrench - VW 049- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
WARNING
a
do
priv
cum
for
Fuel in the supply line is kept under pressure; depressurize

en
ng
t.
yi Co
system before disconnecting hoses. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1.4.1 Disconnect
– Place the Wrench - VW 049- on connector.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
– Pull the connection body tube -arrow- disconnecting it.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– To remove the lock, move it towards -arrows-.

m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Whenever a quick coupling is undone, the lock must be replaced.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1.4.2 Connect
– Use a new lock, installing it onto the connector -arrow-.

– Remake connection. The ring for checking the correct assem‐

bly -arrow- is released from the lock when pulling the connec‐
tor in the uncoupling direction.
Note
Make sure the quick coupling is totally engaged (install it until you
hear a characteristic “click”).
1.5 Fuel pump for cold start - V263- - re‐

BJA and BPA agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note
♦ Keep fuel tank always replenished regardless of the season

of the year.
♦ The cold start system operates at ambient temperature of 15
°C or less.
I ⇒ page 132
II ⇒ page 133
III ⇒ page 133
1.5.1 Part I
Engine compartment.
1 - Petrol supply reservoir

2 - Hose agen
AG. Volkswagen AG d
oes
ksw
❑ For aeration the petrol byV
ol not
gu
ara
reservoir. rised
nte
ho eo
❑ Hose fastening with de‐ aut ra
c
s
formable clamp. s
ce
le
un
pt
❑ Replace clamp and in‐
an
d
itte
stall using pliers Clamp
y li
erm
ab
pliers - VW 004V- or
ility
ot p
Clamp pliers - VAG
wit
1275- .
is n
h re
ole,
3 - Hose
spec
❑ For replenishing petrol
t to the co
reservoir.
4 - Cold start system gasoline
rrectne
tank
❑ For removal, remove
s
right front and wheel
s o
case protector ⇒ Gen‐
cial p
f in
eral body repairs, exte‐
form
mer
rior; Rep. gr. 66 ; Exter‐
atio
m
nal equipment .
o
n
c
i
or
n
5 - Supply tubes
thi
te
sd
va
❑ To the Cold start valve -

i
o
pr
cum
N17- .
r
fo
en
ng
t.
yi
6 - Venting tubes
Co
Cop py
ht. rig
❑ To the air filter. rig ht
py by
co Vo
by lksw
7 - Supply tubes Prote
cted AG.
agen
❑ To Throttle valve control

unit - J338- .
8 - Cold start valve - N17-
❑ With 3-ways.
❑ Fastening nuts 4 Nm.
9 - Ventilation valve
❑ Unidirectional.
❑ To activated charcoal filter.
❑ Blue pipes.

10 - Maximum supply mark

❑ Do not exceed maximum indication limit.
1.5.2 Part II
Front right wheel case.
1 - Eyelet
❑ Use neutral soap for
easier installation.
2 - Hose
❑ For ventilating petrol
reservoir.
❑ Hose fastening with de‐
formable clamp.
pliers - VW 004V- or
Clamp pliers - VAG
1275- .
3 - Hose
❑ For replenishing petrol
reservoir.
4 - Lines
❑ For supply.
❑ For Cold start fuel pump
- V263- for Cold start wagen AG. Volkswagen AG does
valve - N17- . olks not
yV gu b ara
ed nte
5 - Fuel pump for cold
tho
ris start - e or
V263- au ac
ss
❑ To remove, disengage
ce
le
un
pt
from tank.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
1.5.3 Part III

s o
cial p
f in
Right front wheel case (petrol reservoir fastening).

form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - 4 Nm
❑ When installing the res‐
ervoir, the hoses and
the Fuel pump for cold
start - V263- must be in‐
stalled.
2 - 2 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Positioning of hoses in the Cold start valve - N17- . -1- Venti‐

lation hose -2-Hose for Cold start fuel pump - V263- for petrol
reservoir -3- Hose for Cold start valve - N17- to the intake
manifold.
1.5.4 Cold start system components - remove

and install
CCRA engine

1 - Gasoline tank
2 - Hose
❑ For ventilation.
formable clamp.
pliers or VAG 1275 - VW
004V- .
3 - Supply hose
❑ For Cold start fuel pump
- V263- for Cold start
valve - N17- .
formable clamp.
004V- .
4 - Fuel pump for cold start - olks
wage es n
ot g
V263- by V ua
ed ran
❑ To remove, disengage oris tee
th or
from tank. ss
au ac
ce
le

un
pt
an
d
itte
❑ With 3-ways.
y li
erm
ab
❑ Fastening nuts 4 Nm.
ility
ot p
wit
is n
6 - Hose
h re
ole,
❑ Aeration, to the air filter.

spec
❑ Hose fastening with de‐ t to the co

formable clamp.
rrectne

004V- .
ss o
7 - Hose
cial p
f inform
❑ Supply, to the Throttle valve module - J338- .

mer
❑ Hose fastening with deformable clamp.

atio
om
❑ Replace clamp and install using pliers Clamp pliers - VW 004V- or Clamp pliers - VAG 1275- .
c
i
or
n thi
te
sd
8 - Ventilation valve
iva
o
pr
❑ Unidirectional.
um
r
fo
en
ng
t.
❑ To activated charcoal filter.
yi Co
Cop py
❑ Blue pipes.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.6 Fuel pump (pre-supply pump) - G6- - re‐

move and install

♦ Wrench or T 10334 - VW 5321/9-
♦ Torque Wrench - 40 to 200 Nm ( 1/2” wdrive)

agen - VAG 1332-AG doe
AG. Volkswagen
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Nylon Wedge - 3409- or Spatula - VW 037-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
1.6.1 Removal
p by
co Vo
by lksw
cted agen
Prote AG.
– Take safety precautions before starting removal ⇒ page 128 .
– Follow cleaning rules ⇒ page 129 .
– Check if the vehicle has code radio; if so, request respective
anti-theft code.
– With the ignition off, disconnect the earth wire from the Battery
- A- .
– Fold rear seat forward.

– Remove the access lid of the Fuel pump (pre-intake pump) -

G6- using the Nylon Wedge - 3409- or Spatula - VW 037- .
WARNING

removing hose.
AG. Volkswagen AG d
agen oes
lksw not
– Remove the d byreturn
Vo
line -1-, supply line -2-, connector
gu
ara -3-, and
connector oris -4- from the Fuel pump (pre-supply pump)
e nte - G6- .
e
th or
au ac
ss
ce
e
Note
nl
pt
du
an
itte
y li
To remove fuel hoses, press the safety key located under the
erm
ab
ility
connection.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove the lock with a Wrench or T 10334 - VW 5321/9- .

rrectness of i
– Remove the Fuel pump (pre-supply pump) - G6- and the open‐
l purpos
ing seal in the fuel tank.

nf
ercia
orm
Note
m
atio
om
n in
c
In case of replacing Fuel pump (pre-supply pump) - G6- , empty

or
thi
e
the old Fuel pump (pre-supply pump) - G6- before disposing it.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
1.6.2 Installation
co Vo
by lksw
cted agen
Prote AG.
– The Fuel pump (pre-supply pump) - G6- should be installed in
reverse order of removal.

Note
AG. Volkswagen AG d
♦ Try not to bend the Fuel gauge sensor - G- during
lksw installation.
agen oes
not
Vo gu
y
♦ Put the new sealing ring of Fuel pump (pre-supply
rise
d b
pump) - G6- ara
nte
in dry condition on fuel reservoir opening.
utho eo
ra
s a c
♦ Lubricate the new sealing ring with fuel only for installing the
s
ce
e
Fuel pump (pre-supply pump) - G6- .
nl
pt
du
an
itte
y li
♦ Observe installation position of the Fuel pump (pre-supply
erm
ab
pump) flange - G6- -arrow-: The marking on the fuel system
ility
ot p
pressurisation pump - G6- should point towards the front of the
wit
, is n
vehicle.
h re
hole
spec
♦ For the SpaceFox/Suran, the -arrow- at the right of return line
es, in part or in w
(blue pipe) in the pump must match the arrow of the fuel tank
t to the co
♦ Check that the fuel hoses are firmly connected.
rrectness of i
♦ Do not confuse the supply and return hoses.
♦ After installation of the Fuel pump (pre-supply pump) - G6- ,
l purpos
check whether the supply, return and vent pipes are still fas‐
tened to the fuel reservoir.
nf
ercia
orm
m
atio
m
1.7 Fuel gauge sensor - G- - remove and in‐

o
n in
or c
stall
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
1.7.1 Removal
yi Co
Cop py
t. rig
gh ht
– Remove Fuel pump (pre-supply pump) - G6- ⇒ page 135 . yri
p by
co Vo
by lksw
cted
– Disconnect the connector from the Fuel gauge sensor - G- by
agen
Prote AG.
displacing the lock -1- and moving it towards -arrow a-.
– Press lock -2- and move the Fuel gauge sensor - G- -3- up‐
wards -arrow b-.
1.7.2 Installation
– Position the Fuel gauge sensor - G- in the Fuel pump (pre-
supply pump) guides - G6- and press downwards until it fits.
– Install the Fuel gauge sensor connector - G- .
1.8 Fuel reservoir - remove and install


lks wage es n
o ot g
♦ Gearbox or engine + gearbox assembly d by V jack - EQ 7081- or ua
ran
Gearbox or engine + gearbox assembly
o
ir se jack - VAG 1383A- tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ VAS 5024A or Standard-type clamp pliers - VW 5162- or Pliers
- VAG 1921-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Nylon Wedge - 3409- or Spatula - VW 037-
cted agen
Prote AG.
1.8.1 Removal
Conditions
• The fuel tank must only be half full.

Note
♦ Empty the fuel tank with a Fuel aspirator and tank - VAS
5190- .
♦ Take safety precautions before starting removal ⇒ page 128 .
– Check if the vehicle has code radio; if so, request respective

anti-theft code.
– With the ignition off, disconnect the earth wire from the Battery
- A- .
– Remove the tank cap.
– Empty the fuel tank and clean around the filling nozzle.
– Fold rear seat forward.
– Disengage the 4-poles connector from Fuel pump (pre-supply
pump) - G6- .
– Disconnect the earth wire connector.
– Remove the fuel tank hoses near the Fuel pump (pre-supply
pump) - G6- .
– Loosen exhaust system. The exhaust system must be fas‐
tened to the body with wire, slightly lowered.
– Remove the heat deflector between the exhaust and the fuel
tank.
. Volkswagen AG
gen AG does
swa
– Loosen supply hose -1- from the filter.
by
Vol
k not
gu
d ara
ise nte
– Remove the clamp from supply thorline near the tank with VAS eo
5024A or Standard-type clamp
s a pliers - VW 5162- or Pliers -
u ra
c
VAG 1921- . s
ce
le
un
pt
– Remove fastening bolts, supporting the fuel tank with the En‐
an
d
itte
y li
gine / gearbox jack - EQ 7081- or Engine / gearbox jack - VAG

erm
ab
1383A- .
ility
ot p
wit
is n
– Lower the fuel tank.

h re
ole,
spec
WARNING
t to the co

rrectne
removing hose.
ss o
cial p
f in
1.8.2 Installation
form
mer
atio
m
Installation is carried out in reverse order of removal, whilst con‐

o
n
c
sidering the following:

i
or
n thi
te
sd
a
♦ Attach the ventilation and fuel hoses without bending them.

iv
o
pr
cum
r
fo
♦ Check that the fuel hoses are firmly connected.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
Once the fuel tank is installed, check that the supply, return and
ventilation hose assemblies are still attached.
1.9 Fuel pump (pre-supply pump) - G6- - check

equipment required
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Wrench or T 10334 - VW 5321/9-

♦ Pressure gauge - VAG 1318-
♦ Adapter - VAG 1318/1-
♦ Flow meter - VAG 1348-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
♦ Control system for relay-controlled circuits - VAG 1466A-

n
t.
yi Co
Cop py
♦ Test probe - EQ 7300- or Test probe - VAG 1527B-
t. rig
gh ht
pyri by
Vo
o
♦ Auxiliary measurement cable set - VAG 1594A- ou Auxiliary
c by lksw
cted agen
measurement cable set - VAG 1594C- Prote AG.
♦ Multimeter - VAG 1715-

♦ Graduated container
♦ ⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations

Check conditions
• Fuse number 33, OK.
• Battery - A- voltage of at least 11,5 V. AG. Volkswagen AG d
agen oes
lksw not
• All electrical components, such as lights dand
by V the rear wind‐
o gu
ara
screen demister, must be turned off. orise nte
th eo
u ra
• If the vehicle is equipped with air sconditioning,
sa it should also c
be off.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
1.9.1 Operation of the electrical supply -
t to the co
check
rrectness of i
Note
l purpos
In the following operations sequence, it may possibly be neces‐
nf
ercia
sary to disconnect the Battery - A- earth wire. Therefore, check if
orm
a code radio is installed. Should that be the case, first obtain the
m
atio
m
anti-theft code.
o
n in
or c
thi
e
– Tilt rear seat forwards.

t
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
– Turn the ignition system on. The Fuel pump (pre-supply pump)
t. rig
gh ht
yri
- G6- must operate in an audible way for approx. 1 second.
p by
co Vo
by lksw
cted agen
If the Fuel pump (pre-supply pump) - G6- does not work:
Prote AG.
– Switch the ignition off.

– Remove the fuse box lid.
– Remove fuse 33 from the ( Fuel pump (pre-supply pump) -
G6- ) fuse box.
– Connect the Remote control - VAG 1348/3A- and Adapter ca‐

ble - VAG 1348/3-3- to the lower contact of fuse 33 (33b
position) to activate the fuel system pressurisation pump - G6-
and to the positive terminal of the Battery - A- (+).
– Activate the Remote control - VAG 1348/3A- .
If the Fuel pump (pre-supply pump) - G6- works:
– Check the activation of the Fuel pump relay - J17- in accord‐
ance with the ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations, using the Control system for relay-con‐
trolled current circuits - VAG 1466A- :
If the Fuel pump (pre-supply pump) - G6- does not work:
– Disconnect the 4-pole connector for the Fuel pump (pre-sup‐
ply pump) - G6- .

– Connect the Test probe - EQ 7300- or Test probe - VAG

1527B- with Auxiliary measurement cable set - VAG 1594A-
or Auxiliary measurement cable set - VAG 1594C- to connec‐
tor external contacts.
– Activate the Remote control - VAG 1348/3A- . The LED should
light up.
If the LED does not light up:
– Locate and eliminate cable interruption, according to⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
The LED lights up (correct power supply):
AG. Volkswagen AG d
agen oes
lksw not
– Remove the Fuel pump (pre-supply pump) - G6- with a d byV
o gu
ara
Wrench or T 10334 - VW 5321/9- . orise nte
h eo
ut ra
– Check if the cables are coupled to the Fuel pump (pre-supply
ss a c
pump) - G6- .
ce
e
nl
pt
du
an
If there is no cable interruption:
itte
y li
erm
ab
– Fuel pump (pre-supply pump) - G6- - damaged, replace
ility
ot p
⇒ page 135 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.9.2 Fuel supply system output - check
rrectness of i
l purpos
Check conditions
• The Fuel pump (pre-supply pump) - G6- supply does not dis‐
nform
ercia
play any irregularities.

m
• Remote control - VAG 1348/3A - , connected.
at
om
ion
c
in t
• Fuel pressure regulator and Fuel pump (pre-supply pump)
or
his
e
pressure in order ⇒ page 175 .

at
do
priv
cum
for
en
ng
t.
Note
yi Co
Cop py
ht. rig
rig ht
The flow of fuel is measured with pressure from the Fuel pump py by
co Vo
(pre-supply pump) in 4.2 bar. For this reason fuel pressure must
by lksw
cted agen
Prote
be checked before measuring the flow.
AG.
Checking process
– Remove fuel filling nozzle cap.
WARNING
Fuel supply hoses are under pressure. Wrap hose connection

with cloth prior to loosening. Next, eliminate pressure by care‐
fully removing hose.

wage es n
Foxy2004
Volks ➤ , Fox 2010 ➤ , Fox 2014 ot g ➤ , SpaceFox 2006 ➤ , SpaceFox 201 ...
b u
ir se
d 4 - Cyl.arinjection
an
tee engine (1.6 l) - Edition 09.2017
tho
u or
– s a fuel supply hose connection -1- and clean the ac
Disconnect sthe
spilled fuel with a cloth.
ce
e
nl
pt
du
an
– Couple the Pressure gauge - VAG 1318- to the fuel supply itte
y li
erm
ab
tube with the Connector - VAG 1318/23- and Adaptor - VAG
ility
ot p
1318/17- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Couple the Pressure gauge - VAG 1318- to Adapter - VAG

1318/11- and Adapter - VAG 1318/1- and put its end in a grad‐
nform
ercia
uated container with at least 3.0-litre capacity.

m
at
– Open the Pressure gauge valve - VAG 1318- . The valve han‐
om
ion
dle will indicate the flow direction -A-.
c
in t
or
his
te
– Activate the Remote control - VAG 1348/3A- , and close the

a
do
riv
valve slowly -B-, until the Pressure gauge - VAG 1318- indi‐
p
cum
or
cates a pressure of 4.2 bar. From this moment on, do not

f
en
ng
t.
yi
change the position of the valve.
Co
Cop py
t. rig
gh
– Empty measuring container.
ht
pyri by
Vo
co lksw
by
– The flow of the Fuel system pressurisation pump - G6- de‐ cted agen
Prote AG.
pends on the Battery voltage - A- . Accordingly, connect
Multimeter - VAG 1715- to the Battery - A- using a Set of aux‐
iliary measuring cables - VAG 1594C- .
– Activate the remote control - VAG 1348/3A- and valve -A- si‐
multaneously during 30 seconds to measure the tension of
Battery - A- .
– Compare the fuel flow with the theoretical value.
Fox and CrossFox

SPACEFOX/SURAN and SPACECROSS/SURANCROSS

15) Minimum amount cm3/30 s
16) Voltage in the Fuel system pressurisation pump - G6- with engine stopped
and Fuel system pressurisation pump - G6- operating (approx. 2 volts less than
the Battery voltage - A- ).
Examples of readings:
During the test, a voltage of 12.5 volts is measured on the Battery
- A- . As with the Fuel pump - G6- voltage is approximately 2 volts
lower than at the Battery - A- , the result is a minimal supply flow
of:
♦ 553.4 cm3/30 s for (Fox and CrossFox)
♦ 542 cm3/30s for (SpaceFox/Suran and SpaceCross/Suran‐
Cross)
If minimum flow is not achieved:
– Check if the supply pipes to the filter present folds or obstruc‐
tions.
If fuel pipes are in order.
– Check fuel flow before fuel filter.
WARNING
Fuel supply pipes are under pressure! Before loosening hose

connections, put a cleaning cloth on connection points. Then
depressurize by carefully pulling the hose.
Note
Press the keys on hose latches.

AG. Volkswagen AG d
agen oes
olksw not
FOX and CROSSFOX d by V gu
ara
rise nte
– Remove supply ut hose -1- from fuel filter inlet and connect it toe or
ho
the Adaptingssset
a
- VAG 1318/98- and the Pressure gauge - ac
VAG 1318- .
ce
e
nl
pt
du
an
itte
y li
– Install the Adapter - VAG 1318/16- on the Adapter - VAG

erm
ab
1318/11- of the Pressure gauge - VAG 1318- and put the hose
ility
ot p
end in a graduated container with a 3-litre capacity.

wit
, is n
h re

hole
spec
es, in part or in w
– Remove supply hose -1- from fuel filter inlet and connect it to
t to the co
the Adapting set - VAG 1318/17- and the Pressure gauge -

VAG 1318- .
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
146
Prote AG.
Rep. gr.20 - Fuel supply system

Note
It is also possible to check the flow after measuring pressure from

the Fuel pump (pre-supply pump) and retention valve, just dis‐
connecting the connection from Adapter - VAG 1318/17- to the
fuel filter.
– Open the Pressure gauge - VAG 1318- valve. The valve points
towards the fuel passage-A-.
– Actuate the Remote control - VAG 1348/3A- , close the valve
slowly -B- until the Pressure gauge - VAG 1318- indicates 4.2
bar. Do not change the valve position.
– Empty measuring container.
– Check flow again.
– Activate the Remote control - VAG 1348/3A- and valve -A-
again, and simultaneously for 30 seconds. Compare the flow
value with the one obtained in the first measurement
If minimum flow is not achieved:
– Remove the Fuel pump (pre-supply pump) - G6- and check
whether there is dirt in the screen filter.
If minimum flow is achieved:
– Replace fuel filter.
If the minimum flow is not reached again:
swage es n
Only if no irregularities have been found so far: byV
olk ot g
ua
d ran
ir se
– Replace Fuel pump (pre-supply pump) - G6- ⇒ pagetho135 . tee
or
au ac
If the desired fuel flow is achieved, but at great cost, we may con‐
ss
ce
le
clude that the fuel supply presents some irregularity (i.e. a tem‐
un
pt
porary fuel supply failure):
an
d
itte
y li
rm
ab
– Reconnect the fuel tubes removed.
pe
ility
ot
wit
, is n
– By using the electric calliper, connect the Multimeter - VAG h re

hole
1715- to contact 1, 4-pole connection cable -arrow- on cable spec

harness.
es, in part or in w
t to the co
– Run the engine and idle it.

– Measure current draw by the Fuel pump (pre-supply pump) -
rrectness of i
G6- . Theoretical value:

l purpos
♦ Maximum 8.2 amperes for (Fox and CrossFox)

♦ Maximum 6.6 amperes for (SpaceFox/Suran and Space‐
nform
ercia
Cross/SuranCross))
m
If the current draw is excessive:

com
tion in
r
– Replace Fuel pump (pre-supply pump) - G6- ⇒ page 135 .

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.9.3 Fuel pump (pre-supply pump) - G6- re‐

tention valve - verify.
Check conditions
• Remote control - VAG 1348/3A-
• Pressure gauge - VAG 1318-
Checking process
This check tests simultaneously the supply hose connections
from the Fuel pump (pre-supply pump) - G6- to the Pressure
gauge - VAG 1318- connection for leaks.
FOX and CROSSFOX
– Remove supply hose -1- from fuel filter inlet and connect it to
the Adapting set - VAG 1318/98- and the Pressure gauge -
VAG 1318- .
– Remove supply hose -1- from genthe fuel
AG. V filter
olksw ageninlet
AG doand connect
it to the Adapter set - VVAG wa1318/17- and the Pressure ot g gauge
lks es n
o
- VAG 1318- . ed by ua
ran
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


end in a 3.0-litre (minimum) graduated container
Note
For that, press the keys on hose connectors.
– Close the valve on the Pressure gauge - VAG 1318- (trans‐

verse valve in relation to the flow direction - position -B-).
– Activate the Remote control - VAG 1348/3A- in quick consec‐
utive intervals, until reaching a pressure of approx. 4.2 bar.
WARNING
The fuel system is kept under pressure, when opening the

valve, hold a container in front of the free connection on the
pressure meter. agen
AG. Volkswagen AG d
o
w es n
olks ot g
byV ua
ed ran
ris tee
– Reduce excess pressure byucarefully
tho opening the valve. or
sa ac
– Check the pressure drop on the Pressure gauge - VAG 1318- .
s
ce
e
nl
After 10 minutes, the pressure should not drop below 2.5 bar.
pt
du
an
itte
y li
If the pressure keeps dropping:
erm
ab
ility
ot p
– Check hose connections for leaks.
wit
, is n
h re
If no irregularity is detected:
hole
spec
– Replace Fuel pump (pre-supply pump) - G6- ⇒ page 135 .
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

swage es n
2 Engine power electronic adjustment (electronic accelerator) - check olk ot g
byV ua
d ran
ir se tee
tho
u or
a ac
1 - Pedal support ss
ce
e
nl
pt
du
2 - Connector
an
itte
y li
❑ Black, 6 poles.
erm
ab
ility
ot p
3 - Accelerator pedal position
wit
, is n
sensor - G79- and Sensor 2 of
h re
hole
accelerator pedal position -
spec
G185-
es, in part or in w
t to the co
4 - 10 Nm
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.1 Electronic accelerator system operation

In the electronic accelerator, the throttle valve is not activated by
a cable. There is no mechanical connection between the accel‐
erator and the throttle valve.
The position of the accelerator is transmitted to the Engine control
unit - J623- by two accelerator position sensors (variable resist‐
ance; stored in a housing), which are connected to the accelera‐
tor.
The position of the accelerator (at the driver's criterion) is the main
input value for the Engine control unit - J623- .
The throttle valve is activated by an electric engine (butterfly el‐
ement) incorporated to the Throttle valve control unit - J338- , in
all load and rotation intervals.
The throttle valve is activated by a butterfly element, according to
data provided by the Engine control unit - J623- .
With the engine turned off and the ignition connected, the Engine
control unit - J623- activates the butterfly element, due to the data
provided by the Accelerator pedal position sensor - G79- and Ac‐

celerator pedal position sensor 2 - G185- . This means that if the

accelerator is half activated, the butterfly element will open pro‐
portionally, that is, the throttle valve will be half opened.
With the engine running (loaded), the Engine control unit - J623-
may open or close the butterfly, regardless the Accelerator pedal
position sensor - G79- and Accelerator pedal position sensor 2 -
G185- .
Accordingly, the throttle valve may, for instance, be completely
open already, even if the accelerator is only half activated. The
benefit is being able to avoid losses from choking, caused by the
throttle valve.
Furthermore, this enables lower fuel consumption and emissions
of pollutants for certain load conditions.
The necessary torque may be obtained by the Engine control unit
- J623- , through an optimal combination between the throttle
valve opening and the over-supply pressure.
It would be a mistake to believe that the electronic accelerator
consists of only one or two components. The electronic throttle is
a system comprised of all the components that contribute to de‐
termining the position of the throttle valve, in order to adjust it and
activate it, such as, the Accelerator pedal position sensor, the
Throttle valve control unit - J338- , the EPC system fault warning
light, the Engine control unit - J623- , etc).
Follow applicable safety measures ⇒ page 128 .
Follow applicable cleaning rules ⇒ page 129 .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Engine power electronic adjustment (electronic accelerator) - check 151

3 Activated charcoal filter system
3.1 Operation
Depending on the local air temperature and pressure, fuel va‐
pours may form over the surface of the fuel in the tank.
The activated charcoal filter system prevents these hydrocarbon
emissions from reaching the air we breathe.
Limited amounts of fuel vapours reach the activated charcoal fil‐
ter, located in the highest point of the tank, through a gravity valve
(which closes at a 45° inclination) and the pressure retention
valve.
The activated charcoal absorbs these vapours like a sponge.
During the vehicle operation and with the lambda control active
(hot engine), the Magnetic valve 1 for the activated charcoal filter
- N80- , also known as regeneration valve, is activated cyclically
by the Engine control unit - J623- , in function of its load and en‐
gine speed (rpm) regime. The opening interval depends on the
input signals.
Intake manifold vacuum aspirates fresh air through the ventilation
opening on the lower part of the activated charcoal filter during
the purging procedure (activated charcoal regeneration). The fuel
vapours stored in the activated charcoal and the fresh air are fed
for combustion in controlled quantities.
The pressure retention valve prevents fuel vapours from being
aspirated directly from the tank, when the Magnetic valve 1 for
the activated charcoal filter - N80- is opened and there is vacuum
in the intake manifold. Accordingly, this ensures priority drainage
for the activated charcoal filter.
In the absence of current (e.g. harness interruption), the Magnetic
valve 1 for the activated charcoal tank - N80- remains closed. The
activated charcoal filter will not be purged.
wage
es ks not
Vol gu
d by ara
e nte
ris
Note tho eo
au ra
c
ss
ce
le
♦ The hose connections are fastened by spring clamps or quick

un
pt
coupling.
an
d
itte
y li
erm
ab
♦ To install the spring clamps, we recommend using the Stand‐

ility
ot p
ard-type clamp pliers - VW 5162 (VWB) - ou - VAS 5024A- .

wit
is n
h re
ole,
Follow applicable safety measures ⇒ page 128 .

spec
Follow applicable cleaning rules ⇒ page 129 .

t to the co
3.2 Activated charcoal filter system components - repair

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
152
agen
Prote AG.
Rep. gr.20 - Fuel supply system
1 - Air venting pipes

tened.
2 - Pressure retention valve
with connection hose
tened.
❑ From the gravity valve in
the fuel reservoir.
3 - Activated charcoal filter
❑ Installation location: in
the right rear wheel
case.
4 - Vent connection
❑ Visible from below.
5 - 10 Nm
6 - Intake manifold with Throt‐
tle valve control unit - J338-
7 - Magnetic valve I for activa‐
ted charcoal tank - N80-
❑ The Activated charcoal
filter solenoid valve I -
N80- will close when the
ignition is off.
❑ The Activated charcoal
filter solenoid valve I - AG. Volkswagen AG d
agen oes
ksw
N80- is activated (by by
Vol not
gu
ara
pulses) via Engine con‐ rised
nte
trol unit - J623- , when ut ho eo
ra
the engine is at the op‐ss a c
erating temperature.
ce
le
un
pt
an
d
8 - Connector
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
3.3 Fuel tank ventilation - check

hole
spec
es, in part or in w

t to the co
♦ Vacuum gauge - VAG 1368-

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Activated charcoal filter system 153

♦ Vacuum pump - VAG 1390 (VWB) - ou - VAS 6213-
Test conditions
• The ignition must be OFF.
Test sequence
– Remove the fuel reservoir nozzle lid.
– Release the breather hose -1- from the activated charcoal filter
on the Magnetic valve I for the activated charcoal filter - N80-
-2-.
– Connect the Vacuum pump - VAG 1390 (VWB) - ou - VAS
6213- and the Vacuum meter - VAG 1368- to hose -1-, as
shown.
– Place the vacuum gauge in -A/B- position.
– Activate the Vacuum pump - VAG 1390 (VWB) - ou - VAS
6213- several times. No vacuum should be created.
If there is vacuum:
– Check if ventilation opening -3- of activated charcoal filter -4-
is clogged, clean if necessary.
AG. Volkswagen AG d
agen oes
If there is no vacuum: olksw not
byV gu
ara
d
– Plug the venting hose -3- and re-activate the vacuum
orise
pump nte
eo
several times. Vacuum should be generated.auth ra
ss c
If there is no vacuum:
ce
le
un
pt
an
d
– Replace the activated charcoal filter.

itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

24 – Mixture preparation - injection

1 Injection system - repair
1.1 General instructions regarding the injec‐

tion system
♦ The Engine control unit - J623- is equipped with a self-diag‐
nosis system. Before carrying out repairs, and for trouble‐
shooting, refer to the event memory. Likewise, check vacuum
hoses and connections (air infiltration).
♦ The fuel hoses in the engine compartment must only be se‐
cured with spring clamps. Using retaining clamps or screwed
clamps is not allowed.
♦ A minimum voltage of 11.5V is necessary for the perfect op‐ n AG. Volkswagen AG do
eration of electrical components. olks
wage es n
o V t gu
by ara
♦ Do not use silicone-based sealants. Silicone residuesris sucked
ed nte
in by the engine do not burn and may damage the t Lambda
ho eo
au ra
Probe - G39- . ss c
ce
le
un
♦ In case of a power supply interruption or if the faulty memory
pt
an
d
is erased, the READINESS code must be generated again.

itte
y li
rm
ab
pe
Safety measures ⇒ page 170 .
ility
ot
wit
, is n
Cleaning rules ⇒ page 171 .
h re
hole
spec
Technical data ⇒ page 171 .
es, in part or in w
t to the co
1.2 Component location
Engines: BAH, BLH, BJA, BPA and CFZA
rrectness of i
Components A to D are not represented in the illustration.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Injection system - repair 155

A - Brake pedal switch - F47-

❑ At the feet compart‐
ment, on the brake ped‐
al.
B - Accelerator position sender
- G79- and Sender 2 of the ac‐
celerator pedal position -
G185-
ment, on the accelerator Volkswagen AG
pedal ⇒ page 150 .swagen AG. does
k not
y Vol gu
C - Clutch pedal switch d b - F36- ara
rise nte
❑ In feet acompartment,
ut
ho on eo
ra
clutchsspedal. c
ce
e
nl
D - Fuel pressure regulator
pt
du
an
itte
y li
❑ On the Fuel pump (pre-
erm
ab
supply pump) - G6- .
ility
ot p
wit
, is n
1 - Cold start system gasoline
h re
tank
hole
spec
❑ BJA and BPA engines
es, in part or in w
t to the co
only.
2 - Connector
❑ Black, 3 poles. rrectness of i
❑ To the Engine speed
l purpos
sensor - G28- .
❑ To remove the Engine
nf
ercia
speed sender - G28- ,

orm
remove intake manifold.

m
atio
om
n in
3 - Connector
or c
thi
e
❑ Black, 4 poles.
t
sd
iva
o
r
❑ To the Intake manifold

rp
cu
o
pressure sensor - G71-

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
156 Rep. gr.24 - Mixture preparation - injection

with the Air intake tem‐

perature sensor - G42- .
4 - Intake manifold
❑ Installation location: On engine block, intake
agen
side.
AG. Volkswagen AG d
o
ksw es n
Vol ot g
6 - Throttle valve control unit - J338- ed by ua
ran
ris tee
7 - Engine speed sensor - G28- autho or
ac
ss
❑ Installation location: On engine block, intake
side.
ce
e
nl
pt
❑ To remove the Engine speed sender - G28- , remove intake manifold.
du
an
itte
y li
❑ Sensor securing bolt’s torque: 5 Nm.
erm
ab
ility
ot p
8 - Engine control unit - J623-
wit
, is n
❑ Fit or remove the connector only with ignition switched off.
h re
hole
spec
❑ Unlock to unslot.
es, in part or in w
❑ For CCRA and CFZA engines, remove lower noise insulation from the front windscreen.
t to the co
9 - Ignition transformer - N152-
❑ With codes for ignition cables, do not confuse.
rrectness of i
❑ ⇒ Item 2 (page 191) .
l purpos
10 - Lambda probe after the catalyser - G130- , 50 Nm
nf
ercia
❑ Installation location: On the exhaust tube, next to the sleeve.
orm
m
atio
m
❑ Installation location: On the exhaust tube, next to the catalytic converter.

o
n in
or c
thi
❑ CFZA engine only, Argentinean version.
te
sd
iva
o
r
11 - Hall Sender - G40-

rp
cu
o
m
f
en
ng
❑ ⇒ Item 8 (page 191) .

t.
yi Co
Cop py
12 - Connector
t. rig
gh ht
yri by
❑ Black, 4 poles. cop Vo
by lksw
cted agen
❑ To the Lambda probe - G39- 1 before the catalytic converter and Lambda probe heating - Z19- .
Prote AG.

14 - Lambda probe - G39- 1 before the catalytic converter, 50 Nm
❑ Installation location: On the exhaust tube, front part (BAH, BLH, BJA and BPA engines).
❑ Installation location: On the exhaust manifold CCRA and CFZA.
15 - Cylinder 1 injector - N30- , Cylinder 2 injector - N31- Cylinder 3 injector - N32- and Cylinder 4 injector -
N33- )
16 - Fuel distributor
17 - Valve
❑ BJA and BPA engines only.
❑ BJA and BPA engines only.
19 - Magnetic valve I for activated charcoal tank - N80-
Engine: CCRA
Components A to D are not represented in the illustration.
Versions Novo Fox and New SpaceFox/Suran have Lambda
Probe after catalytic converter - G130-

A - 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-
ment, on the accelerator
pedal ⇒ page 150 .
C - Clutch pedal switch - F36-
❑ In feet compartment, on
clutch pedal.
D - Fuel pressure regulator
❑ On the Fuel pump (pre-
supply pump) - G6- .
olkswagen AG
en AG. V
1 - Cold start system gasoline olks
wag does
not
tank ed
byV gu
ara
ris nte
2 - Connector aut
ho eo
ra
s c
❑ Black, 3 poles. s
ce
le
un
pt
❑ To the Engine speed
an
d
itte
sensor - G28- .
y li
rm
ab
pe
ility
ot

wit
, is n
remove intake manifold. h re

hole
spec
3 - Connector
es, in part or in w
t to the co
❑ Black, 4 poles.
❑ To the Intake manifold
pressure sensor - G71-
rrectness of i
with the Air intake tem‐

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

perature sensor - G42- .

5 - Intake manifold
❑ Installation location: On engine block, intake side.
7 - Throttle valve control unit - J338-
❑ Fit or remove the connector only with ignition switched off.
8 - Engine speed sensor - G28-
❑ Placed under the windscreen lower covering.
10 - Ignition transformer - N152-
❑ With codes for ignition cables, do not confuse.
❑ ⇒ Item 2 (page 191) .
❑ ⇒ Item 8 (page 191) .
12 - Connector
❑ Black, 4 poles.
❑ For Lambda probe - G39- before the catalytic converter and Lambda probe heating - Z19- .
14 - Lambda probe - G39- , 50 Nm
❑ Located in the catalytic converter, near the exhaust manifold.
15 - Cylinder 1 injector - N30 - , Cylinder 2 injector - N31 - , Cylinder 3 injector - N32 - and Cylinder 4 injector
- N33-
AG. Volkswagen AG d
16 - Fuel distributor agen oes
olksw not
y V gu
b ara
17 - Unidirectional valverise
d
nte
tho eo
u
18 - Magnetic valve
ss a I for activated charcoal tank - N80- ra
c
ce
le
un
pt
an
d
itte
y li
1.3 Injection components - remove and in‐

erm
ab
ility
ot p
stall
wit
is n
h re
ole,
Engines: BAH, BLH, BJA and BPA

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
159
c by lksw
cted agen
Prote AG. 1. Injection system - repair
A - Coolant temperature sen‐

sor - G62-
❑ Installation location: On
the cooling system
hose, next to the radia‐
tor.
❑ From the Engine control
unit - J623- .
❑ If necessary, depressu‐
rize the system before
removal.
❑ Resistance values be‐
tween contact 1 and 2 AG. Volkswagen AG d
⇒ page 165 agen oes
olksw not
yV gu
❑ Black Connector, 2 rised b ara
nte
poles. ut
ho eo
ra
a
❑ Gold plated connector ss c
ce
le
contacts.
un
pt
an
d
itte
1 - Connector
y li
rm
ab
pe
ility
ot
J623- .
wit
, is n
h re
❑ Connect or disconnect
hole
spec
the connector only with
es, in part or in w
ignition switched off.
t to the co
rrectness of i
❑ For the injection system,
l purpos
lambda adjustment,
Magnetic valve I for ac‐
tivated charcoal tank -
nform
ercia
N80- , knock adjust‐

ment, speed limit, igni‐
m
a
com
ti
tion and self-diagnosis.
on in
r
te o
❑ When replacing the En‐

thi
s
gine control unit - J623- ,

iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

adjust to the Immobiliser

❑ From the Engine control unit - J623- .
4 - 3 Nm
5 - Connector
❑ Black, 4 poles.
❑ From the Intake manifold pressure sensor - G71- with the Air intake temperature sensor - G42- .
AG. Volkswagen AG d
agen
❑ Gold plated connector contacts.
Vol
ksw oes
not
g y ua
db r
6 - Connector ris
e an
tee
tho or
❑ Black, 3 poles. ss au ac
❑ From Engine speed sensor - G28- .
ce
le
un
pt
an
d

itte
y li
rm
ab
7 - Air filter set
pe
ility
ot
wit
❑ Remove and install the air filter set ⇒ page 168 , ⇒ page 168
, is n
h re
❑ Disassemble and assemble ⇒ page 166 .
hole
spec
es, in part or in w
8 - Fastening clip
t to the co
❑ Observe model.
9 - Cable guide
rrectness of i
❑ Fastened to the fuel distributor.
l purpos
10 - Connector
❑ Black, 2 poles.
nform
ercia
❑ From the Cylinder 1 injector - N30- , Cylinder 2 injector - N31- , Cylinder 3 injector - N32- and Cylinder
m
a
4 injector - N33- .
com
11 - Supply tubes tion in

r
te o
thi
s
iva
❑ Black with white mark.

do
r
rp
cum
❑ Fasten with spring-type clamps.

fo
en
ng
t.
yi
Co
Cop py
t.
❑ From the fuel filter.
rig
gh ht
pyri by
Vo
co
12 - 10 Nm
by lksw
cted agen
Prote AG.
13 - Fuel distributor with injectors
14 - 25.0 Nm
15 - Connector
❑ Black, 6 poles.
16 - For Magnetic valve I for the activated charcoal tank - N80-
❑ Fasten with spring-type clamps.
17 - For brake servo
19 - Seal
❑ Replace.
❑ Check installation position.

20 - Lambda probe - G39- 1 before the catalytic converter, 50 Nm

❑ Installation location: On the exhaust tube, front part.
❑ Only lubricate the thread with -G 052 112 A3- ; do not reach the grooves in the Lambda probe - G39-
body.
❑ Remove and install with the Set of sockets for Lambda probe - 3337- .
❑ Power is supplied to heat the Lambda probe - G39- through the Fuel pump relay - J17- .
21 - Connector fitting
❑ Black, 4 poles.
❑ To the Lambda probe - G39- 1 before the catalytic converter and Lambda probe heater - Z19- .
❑ Contacts 3 and 4 gold plated.
❑ Installation location: On engine block, intake side.
23 - Lambda probe 2 - G108- after the catalytic converter, 50 Nm
❑ Installation location: On the exhaust tube, next to the sleeve.
❑ Only lubricate the thread with -G 052 112 A3- ; do not reach the grooves in the Lambda probe 2 - G108-
body.
❑ Power is supplied to heat the Lambda probe 2 - G108- through the Fuel pump relay - J17- .
❑ When removing, remove the lower right cover of the underbody and the 4-pole connector cover from
Lambda probe 2 - G108- .
AG. Volkswagen
24 - Connector fitting ksw
agen AG do
es n
Vol ot g
❑ Brown, 4 contacts. ed by ua
ran
ris tee
❑ To the Lambda probe 2 - G108- after the catalytic
utho converter and Lambda probe heating - Z19-
or .
a ac
❑ Contacts 3 and 4 gold plated. ss
ce
le
un
pt
25 - 5 Nm
an
d
itte
y li
erm
ab
26 - Guide tube
ility
ot p
❑ To the oil dipstick.

wit
is n
h re
27 - 3 Nm
ole,
spec
28 - Clip
t to the co

29 - Seal
rrectne
❑ Replace.
s
30 - Sealing plug
s o
cial p

inform
mer
31 - Cooling system thermostat valve body

atio
om
n
c
i
or
n thi
e
Engines: CCRA and CFZA

t
sd
iva
o
pr
cum
Versions Novo Fox and Novo SpaceFox/Suran have Lambda

r
fo
en
ng
Probe after catalytic converter - G130-

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 - Connector
J623- .
❑ Connect or disconnect
the connector only with
ignition switched off.
❑ For the injection system, AG. Volkswagen AG d
lambda adjustment, agen oes
olksw not
magnetic valve I for the ed byV gu
ara
activated charcoal tank, horis nte
eo
knock adjustment, aut ra
c
speed limit, ignition and ss
ce
e
self-diagnosis.
nl
pt
du
an
itte
❑ When replacing the En‐
y li
erm
ab
gine control unit - J623- ,
ility
ot p
adjust to Immobilizer
wit
control unit - J362-
, is n
h re
⇒ page 182 .
hole
spec
3 - Connector
es, in part or in w
t to the co
❑ Black, 4 poles.
❑ From the Intake mani‐
fold pressure sensor -
rrectness of i
G71- with the Air intake
l purpos
temperature sensor -
G42- .
❑ Gold plated connector
nf
ercia
o
contacts.
rm
m
atio
m
4 - Connector
o
n in
or c
❑ Black, 3 poles.
thi
te
sd
iva
❑ From Engine speed
o
r
rp
cu
sensor - G28- .
o
m
f
en
ng
t.
yi
Co
op py
. C rig
ht ht
rig
remove intake manifold. py by
co Vo
by lksw
cted
5 - Air filter set
agen
Prote AG.
❑ Disassemble and assemble ⇒ page 166 .

6 - Fastening clip
❑ Observe model.
7 - Cable guide
❑ Fastened to the fuel distributor.
8 - Connector
❑ Black, 2 poles.
❑ From the Cylinder 1 injector - N30- , Cylinder 2 injector - N31- , Cylinder 3 injector - N32- and Cylinder
4 injector - N33- .
9 - Fuel supply lines
❑ Fasten with spring braces.
❑ From the fuel filter.
10 - 10 Nm
11 - Fuel distributor with injectors

12 - 25.0 Nm
13 - Connector
❑ Black, 6 poles.
❑ For Throttle valve control unit - J338- .
14 - For Magnetic valve I for the activated charcoal tank - N80-
❑ Fasten with spring braces.
15 - For brake servo
17 - Seal
❑ Replace.
❑ Check installation position.
18 - Lambda probe - G39- before the catalytic converter, 50 Nm
❑ Installation location: On the exhaust tube, front part.
❑ Lubricate only the thread with High-temperature paste - G 052 112 A3- ; ensure that the High-temperature
paste - G 052 112 A3- does not reach the grooves on the body of the Lambda probe - G39- .
❑ Power is supplied to heat the Lambda probe - G39- through the Fuel pump relay - J17- .
19 - Connector
❑ Black, 4 poles.
❑ For the Lambda probe - G39- before the catalytic converter and Lambda probe heating - Z19- .
❑ Contacts 3 and 4 gold plated.
❑ Installation location: On engine block near to the gearbox, intake side.
AG. Volkswagen AG d
agen
21 - 5 Nm Volksw
oes
not
gu
by ara
d
22 - Guide tube orise nte
eo
th
❑ To the oil dipstick.ss au ra
c
ce
e
23 - 3 Nm
nl
pt
du
an
itte
y li
24 - Clip
erm
ab

ility
ot p
wit
, is n
25 - Seal
h re
hole
❑ Replace.
spec
es, in part or in w
t to the co
26 - Connector
❑ Black, 4 poles.
❑ From Coolant temperature sensor - G62- .
rrectness of i

l purpos
27 - Sealing plug
nf
ercia
orm

m
atio
om

n in
or c
thi

te
sd
iva
❑ Resistance values between contact 1 and 2 ⇒ page 165

r
rp
cu
o
m
f
en
ng
29 - Cooling system thermostat valve body

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
164
c by lksw
cted agen
Rep. gr.24 - Mixture preparation - injection Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V
Fox 2004 ➤ , Fox 2010ed➤b , Fox 2014 ➤ , SpaceFox 2006 ➤
y gu , SpaceFox 201 ...
ara
is ne
thor 4 - Cyl. injection engine (1.6 l) - tEdition
eo 09.2017
au ra
ss c
Resistance values of the Coolant temperature sensor - G62-
ce
e
nl
pt
du
an
The diagram is divided into two temperature regions:
itte
y li
erm
ab
A - from 0...50 ℃
ility
ot p
wit
, is n
B - from 50...105 °C
h re
hole
spec
Sample reading:
es, in part or in w
t to the co
♦ 30° C in region A corresponds to a resistance of 1.5...2.0 kΩ.
♦ 80° C in region B corresponds to a resistance of 275...375 Ω.
rrectness of i
l purpos
1.4 Intake manifold - remove and install
nf
ercia
orm
m
atio
m
1 - Seal
o
n in
or c
thi
te
sd
iva
2 - Throttle valve control unit -
o
r
rp
cu
J338-
o
m
f
en
ng
t.
yi
❑ When replacing, adjust
Co
op py
the Engine control unit - t. C rig
gh ht
yri
J623- to the Throttle p by
co Vo
valve command unit -
by lksw
cted agen
Prote
J338- ⇒ page 182 .
AG.
3 - 7 Nm
4 - 25.0 Nm
5 - Intake manifold
6 - Seal
moval.
❑ Observe installation po‐
sition.
7 - Seal
8 - Intake manifold pressure
sensor - G71- with Air intake
temperature sensor - G42-
❑ Resistance values of
the Air intake tempera‐
ture sensor - G42- be‐
tween contacts 1 and 2.
⇒ page 166
9 - 3 Nm
❑ Observe indications on
installation
⇒ page 168 .

Resistance values for the Air intake temperature sensor - G42-

The diagram is divided into two temperature regions:
A - from 0...50° C.
B - from 50...105° C.
Sample reading:
♦ 20° C in region A corresponds to a resistance of 2.3...2.6 kΩ.
♦ 80° C in region B corresponds to a resistance of 290...330 Ω.
1.5 Fuel distributor with injectors - removal and installation
1 - Fuel distributor
⇒ page 173 .
❑ Check fuel pressure
regulator ⇒ page 175 .
2 - 8 Nm
3 - Clip
tened.
❑ Observe the proper
seating in the injection agen
AG. Volkswagen AG d
oes
valve and Fuel rail. olksw not
y V gu
d b ara
4 - Seal rise nte
tho eo
u ra
❑ Replace after every re‐ ss a c
moval.
ce
le
un
pt
❑ Lightly lubricate with en‐

an
d
itte
y li
gine clean oil before in‐

rm
ab
stallation.
pe
ility
ot
wit
, is n
5 - Cylinder 1 injector - N30- ,

h re
Cylinder 2 injector - N31- Cyl‐

hole
spec
inder 3 injector - N32- and Cyl‐

es, in part or in w
inder 4 injector - N33- )

t to the co
❑ Resistance between
valve contacts: 12... 17
rrectness of i
Ω.
6 - Seal
l purpos

sition.
nform
ercia
❑ Replace when dam‐

m
aged.
com
tion in
r
7 - Fuel supply lines

te o
thi
s
iva

do
r
rp
cum
❑ Fasten with spring bra‐

fo
en
ng
ces.
t.
yi Co
Cop py
t. rig
gh ht
yri by
❑ From the fuel filter. cop Vo
by lksw
cted agen
Prote AG.
1.6 Air filter - disassembly and assembly

Remove and install air filter case ⇒ page 168 ⇒ page 168

1 - Lower part of the air filter

case
2 - Rubber base
3 - 3 Nm agen
AG. Volkswagen AG d
oes
lksw not
❑ Observe indications
by
Vo on gu
ara
installation
rised
nte
⇒ page
au
t 168 .
ho eo
ra
ss c
4 - Seal
ce
e
nl
pt
du
❑ Ensure firm seating.
an
itte
y li
erm
ab
ility
aged.
ot p
wit
, is n
5 - Air intake nozzle
h re
hole
spec
6 - Cap
es, in part or in w
t to the co
7 - Upper part of the air filter
case
rrectness of i
8 - Sealing gasket
l purpos
sition.
nf
ercia
aged. orm
m
atio
9 - Filter element
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 - Air duct
2 - Clamp
❑ Remove with VAS
5024A or Standard type
clamp pliers - VW
5162- .
3 - Upper part of filter air
4 - 1.6 Nm
5 - Filtering element
6 - Lower part of filter air
7 - 8 Nm
8 - Air intake nozzle
9 - 1.2 Nm
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Air filter (BAH, BLH, BJA and BPA engines - remove and install
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.6.1 Removal
– Remove the crankcase air vent hose -1- from the air filter case.
– Remove aeration hose from Cold start valve - N17- , left side
of air filter case (Engines BJA and BPA).
– Remove the air filter case from the supports and the Throttle
valve control unit - J338- -arrows- and remove the air filter
case.

1.6.2 Installation
– Installation is performed in reverse sequence to the removal.
Note
♦ To fasten the filter upper part to the filter base as well as the
air intakes and the Intake air temperature sender - G42- and
Air intake temperature sender - G71- , serial self-locking bolts
are used. If these screws are loosened or tightened with a
power screwdriver, the threads on the upper part of the air filter
set can be damaged.
♦ For that reason, using a power screwdriver is only allowed
when:
♦ the drill speed is 200 rpm at most,
♦ a torque of 3 Nm at most is adjusted.
CCNA and CFZA engines
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
1.6.3 Removal
o
cial p
f inform
mer
– Pull off intake air duct -1-.

atio
m
– Loosen spring clamp -2- with the VAS 5024A or Standard type
o
n
c
clamp pliers - VW 5162- and pull of air duct from the upper part
or
n thi
e
of filter air set.

t
sd
iva
o
pr
cum
– Remove the fastening bolt-arrow- for the air filter set.

r
fo
en
ng
t.
yi
– Tilt the Battery - A- cover forward.
Co
Cop py
t. rig
gh ht
– Move the air filter set upwards. yri
p by
co Vo
by lksw
cted
– Remove air filter set.
agen
Prote AG.
1.6.4 Installation
– Seat air filter set on the rubber supports -arrows-.

– Press air filter set downwards onto the pins.

– Tighten fastening screws to 8 Nm.en AG. Volkswagen AG
ag does
ksw n
– Fasten the air duct with the Vol
by spring clamp on the upper partgof
ot
ua
the air filter set -2-. rised ran
te
ho eo
ut
– Install intake air sduct
sa on intake nozzle -1-. ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
1.7 Safety measures
nform
mercia
a
com
tio
WARNING
n in
r
te o
thi
s
iva
The fuel system is under pressure. Before loosening hose con‐

do
r
nections or opening checking junction, place a cloth around

rp
cum
fo
them. Then, eliminate the pressure, by carefully removing the

en
ng
t.
yi
hose and loosening the closing screw.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
To avoid personal injuries and/or injection and ignition system cted agen
Prote AG.
damage, observe the following:
♦ For safety reasons, fuse 33 must be removed from the fuse
box before opening the fuel system.
♦ Do not touch or remove the ignition cables while the engine is
running or when the engine is starting.
♦ Only connect or disconnect the injection and ignition system
cables (and measuring device cables) with the ignition switch‐
ed off.
WARNING

space:
positions.
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
and have them operated by a second mechanic.
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.

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

starting:
– Disconnect the 4-pole connector from the Ignition transformer
- N152- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
1.8 Cleaning rules

i
o
pr
cum
r
fo
en
ng
For cleaning, carefully observe these “5 rules” when working on

t.
yi Co
op
the fuel supply/injection system: C py
t. rig
gh ht
yri by
♦ Thoroughly clean the connections and surrounding areas be‐ cop Vo
by lksw
fore disconnecting them. cted agen
Prote AG.
♦ Place parts on clean surface and cover them. Use lint-free

cloths!
♦ If the repair work will not be performed immediately, exposed
components must be covered or carefully preserved.
♦ Install clean components only. Remove spare parts from pack‐
aging just prior to installation. Do not install components that
have been stored outside of packaging (i.e. inside a tool box,
etc.).
♦ With the system open: If possible, avoid using compressed air.
Do not move vehicle, if possible.
1.9 Technical Data

Engine codes BAH BLH BJA BPA CCRA/CFZA
Idle speed
check
Idle speed rp 710...81017) 710...81017) 710...81017) 710...81017) 710...81017)
operation m
without air
conditioning
Idle speed rp 790...89017) 790...89017) 790...89017) 790...89017) 770...87017)
operation m
with air con‐
ditioning18)
Engine control
unit19)

Engine codes BAH BLH BJA BPA CCRA/CFZA

System ME 7 5 10 BoschME 7 5 10 ME 7 5 10 Bosch ME 7 5 10
21)
ME 7 5 30 Bosch 20)
Bosch Bosch 22) 23)
Replace‐ ⇒ Replacement ⇒ Replacement ⇒ Replacement ⇒ Replacement ⇒ Replacement

ment part part CD part CD part CD part CD part CD
number
Speed limit rp From approxi‐ From approxi‐ From approxi‐ From approxi‐ From approxi‐
m mately 5700 mately 5700 mately 5700 mately 5700 mately 6500
17) Non-adjustable.
18) Non-adjustable.
19) Replace the Engine control unit - J623- ⇒ page 181 .

20) ME 7.5.20 as from 09.2006.
21) ME 7.5.20 as from 02.2006.
22) 4GV for the SQ 200 gearbox (gear selection mechanism)
23) 9GV as of 04.2013
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Component checks
2.1 Injection valves - check

equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m

o
n
c
i
or
♦ Auxiliary measuring cable set - VAG 1594C-

thi
te
sd
iva
o
r
♦ Digital potentiometer (included in VAG 1594C) - VAG 1630-

p
cum
r
fo
en
ng
♦ Graduated container
t.
yi Co
Cop py
t.
Check sealant and jet form
rig
gh ht
pyri by
Vo
o
by c
Test conditions
lksw
cted agen
Prote AG.
• The fuel pressure must be correct, check ⇒ page 175 .
Test sequence
– Remove air filter set ⇒ page 168 .
– Disconnect the 4-pole connector from the Coolant tempera‐
ture sensor - G62- -arrow-.
2. Component checks 173

Engines: BAH, BJA, BPA, CCRA and CFZA
Engine: BLH
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
– Disconnect the 4-pole connector from the Ignition transformer s
ce
le
- N152- -arrow-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Connect the Digital potentiometer (included at VAG 1594 C) -
o
cial p
f
VAG 1630- with the Auxiliary measuring cable set - VAG
1594A- to connector contacts 3+4 and adjust the connected inform
mer
side to 15 kΩ.
atio
om
n
c
Engine: CCRA
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Connect the Digital potentiometer (included at VAG 1594 C) -

VAG 1630- using the Auxiliary measuring cable set - VAG
1594C- to connector contacts -1-+-2- and adjust connected
side to 15 kΩ.
– Disconnect the injection valve harness in the fuel distributor.
– Remove the fuel distributor with all injection valves from en‐
gine cylinder head (fuel pipes remain connected).
– Keep a small graduated container under the injection valve to

be tested and remove the connectors from the remaining in‐ AG. Volkswagen
jection valves. lksw
agen AG do
es n
o ot g
yV ua
– A second person must operate the Starter - B-ri.seThe
d b injection ran
tee
valve should inject in pulses. ut
ho
or
sa ac
– Repeat test on the other injection valves. Ensure
s
that only the
ce
le
injection valve being tested is connected.

un
pt
an
d
itte
y li
– Then check the injector valve sealant. Fuel loss cannot exceed
rm
ab
2 drops a minute.
pe
ility
ot
wit
, is n
If fuel loss is greater:
h re
hole
spec
es, in part or in w
t to the co
– Replace the damaged injection valve.
The injection valve is installed in the reverse order, observing the
following:
rrectness of i
♦ Rings on all injection valves should be replaced and thorough‐
l purpos
ly lubricated with clean engine oil.

♦ Place the injection valves vertically and in their proper position
nform
ercia
in the fuel distributor and fasten them with safety clips.

m
a
com
t
♦ Install the fuel distributor with the injection valves on the en‐
ion in
gine cylinder head and press down uniformly.
r
te o
thi
s
iva
do
r
2.2 Residual pressure and fuel pressure

rp
cum
fo
en
g
regulator - check
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
♦ Fuel pressure regulator adjusts fuel pressure to around 4.2

bar.
♦ The fuel pressure regulator is in the Fuel pump.


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Pressure gauge - VAG 1318-

♦ Adapting cable - VAG 1348/3A-
Test sequence:


G6- ) fuse box.
WARNING

– Disconnect fuel supply pipes connection -1- and clean spilled

fuel with a cloth. (BAH, BLH and CFZA Engines
gen AG
only).
. Volkswagen AG
d a oes
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect fuel supply pipes connection -1- and clean spilled
fuel with a cloth. (BJA, BPA and CCRA Engines only).
rrectness of i
Note
l purpos
To unlock the fuel line, press the safety ring key. nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Connect the Pressure gauge - VAG 1318- with the Adapter set
- VAG 1318/23- and the Adapter - VAG 1318/17- to the supply
pipes.
– Connect the Pressure gauge - VAG 1318- with the Adapter set
- VAG 1318/7- , Adapter - VAG 1318/14- , Adapter -
VAG 1318/17- to the fuel rail hose.
– Open the pressure gauge valve. The valve will point towards
flow direction-A-.
– Put fuse 33 of Fuel pump (pre-supply pump) - G6- back in the
fuse box.
– Start the engine and keep it idling.
AG. Volkswagen AG d
– Measure fuel pressure. lksw
agen oes
not
Vo gu
y
♦ Theoretical value: approx. 4.2 bar rise
d b ara
nte
tho eo
If the theoretical values is not obtained: s au ra
c
s
ce
e
nl
pt
du
an
itte
– Check that the Fuel pump (pre-supply pump) - G6- is gener‐
y li
erm
ab
ating and maintaining this pressure ⇒ page 141 .
ility
ot p
wit
– Check fuel pressure regulator ⇒ page 179 .
, is n
h re
hole
If the theoretical values is obtained:
spec
es, in part or in w
t to the co
– Check sealing and retention pressure, whilst keeping an eye
on the pressure drop on the Pressure gauge - VAG 1318- .
rrectness of i
After 10 minutes, a minimum pressure of 2.5 bar must be ob‐
tained.
l purpos
If retaining pressure drops below 2.5 bar:
nform
ercia
– Start the engine and keep it idling.

m
at
om
io
– When the pressure is reached, turn the ignition off, while clos‐
n
c
in t
r
ing the Pressure gauge - VAG 1318- valve (transverse valve

o
his
te
in the direction of the passage -arrow-).

a
do
priv
cum
or

f
en
ng
t.
yi Co
If the pressure drops again: t. Cop py
rig
gh ht
yri
– Check the Fuel pump (pre-supply pump) - G6- ⇒ page 148 p by
co Vo
retention valve.
by lksw
cted agen
Prote AG.
– Check fuel pressure regulator ⇒ page 179 .
WARNING

If the pressure does not drop:

– Check hose connections, fuel distributor rings and injection
valves for leaks.
– Check the Pressure gauge - VAG 1318- for leaks.

AG. Volkswagen A
Fox 2004 ➤ , Fox o2010 agen
ksw ➤ , Fox 2014 ➤ , SpaceFox 2006 ➤ , SpaceFox 201 ...
G do
es n
V l ot g
ed by 4 - Cyl. injection engine
ua
ra (1.6 l) - Edition 09.2017
ris nte
tho eo
2.2.1 Fuel pressure regulator - check au ra
ss c
ce
e
nl
pt
Test conditions
du
an
itte
y li
• Retention valve for Fuel pump (pre-supply pump) - G6- OK:
erm
ab
ility
check ⇒ page 148 .
ot p
wit
, is n
Test sequence
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
G6- ) fuse box.
l purpos
– Connect the Remote control - VAG 1348/3A- and Adapter ca‐

ble - VAG 1348/3-2- or Adapter cable - VAG 1348/3-3- to the
lower contact of fuse 33 (29th position) to activate the Fuel
nf
ercia
pump - G6- and the positive terminal of the Battery - A- (+).
orm
m
atio
om
WARNING
n in
or c
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
them. Next, eliminate pressure by carefully removing the hose.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disconnect fuel supply pipes -1- from fuel filter outlet.
• Return lines -2- (blue), keep connected
• Supply pipes -3- (black), keep connected.
• Fuel supply pipes (from filter outlet to engine) -4- connect to
the measuring equipment outlet.
Note
To disconnect the fuel tubing, press the safety ring key.
– Connect the Pressure gauge - VAG 1318- with Adapting set -

VAG 1318/23- and Adapter - VAG 1318/17- to the fuel filter
outlet -1-.
– Close the blocking valve on the Pressure gauge - VAG 1318-
(valve transverse to the flow direction position -B-) .
– Activate the Remote control - VAG 1348/3A- for approximately
10 seconds to fill the fuel tank and generate system pressure
of approximately 4.2 bar.
After 10 minutes, the pressure should not have dropped below
2.5 bar.
If the pressure drops further:
– Check line connections for leaks.
If no flaw is found in the pipes:
– Replace fuel pressure regulator.

3 READINESS code
Function
The READINESS code is an eight-digit code indicating the status
of relevant diagnoses for exhaust gases.
Whenever a system diagnostics (e.g.secondary air system) is
successfully conducted, the corresponding digit in the digital code
changes its status.
Diagnosis is performed at regular intervals during normal vehicle
operation. After doing repairs on an exhaust gas system, it is ad‐
visable to generate the READINESS code, to ensure that all
systems are functioning properly. If a fault is identified during di‐ n AG. Volkswagen AG do
agnosis, it will be saved in the event memory. wage es n
olks o V t gu
by ara
The READINESS code is erased every time the event memory ris
ed is nte
erased or when there is interruption in the power supply
au
t to the
ho eo
ra
Engine control unit - J623- . ss c
ce
e
nl
pt
3.1 Creating and Interpreting the READI‐
du
an
itte
y li
NESS code
erm
ab
ility
ot p
⇒ Vehicle diagnostic tester
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Engine control
ksw unit - J623-
A AG do G. Volkswagen
agen es n
Vol y
ot gu
db ara
rise nte
tho eo
au ra
4.1 Engine
ss control unit - J623- - remove and c
ce
le
install
un
pt
an
d
itte
y li
– Before removing the Engine control unit - J623- first check the
erm
ab
Engine control unit - J623- and also the coding of the Engine
ility
ot p
wit
is n
h re
ole,
4.1.1 Removal
spec
t to the co
rrectne
– Disconnect the fitting connector -arrow- from Engine control
unit - J623- and remove it.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Press clips -arrows- outwards and pull the Engine control unit Prote
cted AG.
agen
- J623- sideways.
– Remove the blade stems and the bottom covering of the wind‐
screen: ⇒ Electric equipment; Rep. gr. 92 ; Windscreen, rear
window and headlight washer and wiper .
– Unlock the connectors from the Engine control unit - J623- and
disconnect them:
– Push the Engine control unit - J623- to the left -arrow- and
remove it.
4.1.2 Installation
– Place the Engine control unit - J623- and press it.
– Connect the connector and lock.
– Adjust the Engine control unit - J623- ⇒ page 182 .
– Refer to the event memory of the new Engine control unit -
J623- and, if necessary, erase the event memory
⇒ page 182 .
– Carry out a test cycle.
– Check again the event memory in the Engine control unit -
J623- ⇒ page 182 .
4. Engine control unit J623 181

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
Fox 2004 ➤ o,riFoxse 2010 ➤ , Fox 2014 ➤ , SpaceFox 2006 nte ➤
eo
, SpaceFox 201 ...
h
4 - Cyl. injection
s aut
engine (1.6 l) - Edition 09.2017 ra
c
s
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
In case the new 9GV Engine control unit - J623- is supplied with‐
wit
, is n
out lateral adapters, remove from the Engine control unit - J623-
h re
hole
to be replaced and install plastic bushings in the new Engine
spec
control unit - J623- , applying a torque of 9 Nm to the lateral
es, in part or in w
t to the co
adapters' fastening bolts.
4.2 Components - adjust
rrectness of i
l purpos
♦ Vehicle diagnostic, testing and information system .
nf
ercia
o
Operation sequence
rm
m
atio
m
– Connect the Vehicle diagnostic, testing and information sys‐

o
n in
c
tem as follows:
or
thi
te
sd
a
– Place the connector of Diagnostic cable to the diagnosis con‐

iv
o
r
rp
cu
nection.
o
m
f
en
ng
t.
Select, in the Vehicle diagnostic, testing and information system
yi Co
op
the “Assisted troubleshooting”.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4.3 Event memory in Engine control unit - J623- - reference and erase


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
♦ Vehicle diagnostic, testing and information system - VAS

o
cial p
5051-
inform
mer

atio
m
5052-
o
n
c
i
or

thi
te
sd
6150-
iva
o
pr
cum
r
fo
♦ Diagnostic cable - VAS 5051/6B-

en
ng
t.
yi Co
♦ Diagnostic cable - VAS 5052/3A- Cop py
t. rig
gh ht
yri
♦ Wireless diagnostic connector - VAS 5054/A- p by
co Vo
by lksw
cted agen
Prote AG.
4. Engine control unit J623 183

Operation sequence
– Connect the Vehicle diagnostic, testing and information sys‐
tem as follows:
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Connect the Diagnostic cable . utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

26 – Exhaust system
1 Removing and installing exhaust sys‐
tem parts
wage
e
olks s no
yV t gu
edb ara
ris nte
Note ut
ho eo
ra
a c
ss
♦ After finishing installation works on the exhaust system, check
ce
le
un
pt
that there is no tension and the distance from the body is suf‐
an
d
itte
y li
ficient. If necessary, loosen double clamp(s) and separate
rm
ab
silencer from the exhaust manifold so they remain, along their
pe
ility
whole lengths, at an enough distance from the body, and the
ot
wit
, is n
supports sustain the weight evenly.
h re
hole
spec
♦ Replace the self-locking nuts.
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
torque
nform
ercia
1.1 Intake manifold, front exhaust tube with

m
a
com
ti
catalytic converter and installation parts

on in
r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Removing and installing exhaust system parts 185

1 - Heat deflector
2 - 12.0 Nm
3 - Exhaust manifold
4 - Sealing gasket
❑ Replace.
5 - Self-locking nut
❑ 25 Nm.
moval.
6 - Double clamp
AG. Volkswagen AG d
moval. ksw
agen oes
not
ol
yV gu
7 - Up to intermediate muffler ised b ara
nte
or eo
h
8 - Self-locking nut s aut ra
c
s
❑ 23 Nm.
ce
le
un
pt
an
d
9 - Front exhaust tube with cat‐

itte
y li
alytic converter
rm
ab
pe
ility
ot
10 - Supporting bearing
wit
, is n
h re
hole
spec
❑ Remove with a Hook -
es, in part or in w
VW 5812- .
t to the co
11 - Connector fitting
rrectness of i
❑ Black, 4 poles.
l purpos
❑ To Lambda probe after

the catalyzes - G130- .
nform
ercia
12 - Lambda probe after the

m
catalyser - G130- , 50 Nm
com
tion in

r
te o
thi
❑ Lubricate only the thread with High-temperature paste - G 052 112 A3- ; the High-temperature paste -
s
iva
do
G 052 112 A3- must not reach the grooves on the body of the Lambda Probe after the catalytic converter
r
rp
cum
fo
- G130- .
en
ng
t.
yi Co
❑ Remove and install with the Set of sockets for Lambda probe - 3337- . t. Cop py
rig
❑ Remove sealing rind in case of leaks and replace it.
gh ht
pyri by
Vo
o
by c lksw
13 - Connector fitting cted agen
Prote AG.
❑ Black, 4 poles.
❑ For Lambda probe - G39- before the catalytic converter and Lambda probe heating - Z19- .
14 - Lambda probe - G39- before the catalytic converter, 50 Nm
❑ Lubricate only the thread with High-temperature paste - G 052 112 A3- ; the High-temperature paste -
G 052 112 A3- cannot reach the grooves on the body of the Lambda probe - G39- .
❑ 40 Nm.
❑ Replace after removal.
16 - Clip
186 Rep. gr.26 - Exhaust system


Versions Novo Fox and Novo SpaceFox/Suran have Lambda
Probe after catalytic converter - G130- (only Argentina version).
1 - Heat shield
2 - 8.0 Nm
3 - Exhaust manifold
❑ For removal, remove
heat deflector and loos‐
en front exhaust tube.
❑ Mounting nuts torque
25.0 Nm.
AG. Volkswagen AG d
❑ Replace after removing agen oes
olksw not
V
of self-locking
ed
bynuts. gu
ara
is nte
or
4 - Lambda probe
au
th - G39- be‐ eo
ra
fore the catalytic
ss converter, 50 c
Nm
ce
le
un
pt
an
d
❑ Lubricate only the

itte
y li
thread with High-tem‐
erm
ab
ility
perature paste - G 052
ot p
wit
112 A3- ; High-tempera‐
is n
h re
ture paste - G 052 112
ole,
A3- cannot reach the
spec
grooves on the body of
t to the co
the probe.
❑ Remove and install with
the Set of sockets for
rrectne
Lambda probe - 3337- .

❑ Remove sealing rind in
ss
case of leaks and re‐

o
cial p
place it.
inform
mer
5 - Sealing gasket
atio
m
❑ Replace.
o
n
c
i
or
n thi
e
6 - Catalytic converter
t
sd
iva
o
r
❑ Integrated to exhaust
p
cum
r
fo
manifold.
en
ng
t.
yi Co
op
7 - Double clamp C py
ht. rig
rig ht
❑ Replace after every re‐ py by
co Vo
moval.
by lksw
cted agen
Prote AG.
8 - To rear silencer
❑ 23 Nm.
10 - Front exhaust manifold with intermediate silencer
11 - Intermediate muffler
12 - Sustaining handle
❑ Remove with a Hook - VW 5812- .
13 - Lambda probe after the catalytic converter - G130- , 50 Nm
❑ Lubricate only the thread with High-temperature paste - G 052 112 A3- ; High-temperature paste - G 052
112 A3- cannot reach the grooves on the body of the probe.

❑ Only Argentina version, Novo Fox and Novo SpaceFox/Suran.
❑ 40 Nm.
15 - Sealing gasket
❑ Replace.
1.2 Muffler with supports

AG. Volkswagen AG d
1 - Bearing agen oes
olksw not
V gu
by ara
2 - Intermediate muffler rised
nte
ho eo
❑ BAH, BLH, BJA and aut ra
c
BPA engines only. ss
ce
le
un
pt
3 - 25 Nm
an
d
itte
y li
rm
ab
pe
ility
❑ Fastened to the body.
ot
wit
, is n
h re
5 - Rear muffler
hole
spec
es, in part or in w
6 - Separation point
t to the co
❑ Identified by a re-entry
on the connecting pipe.
rrectness of i
❑ Intermediate and rear
muffler are assembled
l purpos
as one part as a stand‐

ard item. For separa‐
tion, rear and intermedi‐
nform
ercia
ate muffler are individu‐

m
al parts and supplied
a
com
ti
with a double clamp for
on in
repair.
r
te o
thi
s
iva
❑ Disconnect the connec‐
do
r
rp
c
tion pipe at the separa‐
um
fo
tion point with the Pneu‐

en
ng
t.
yi
matic saw or EQ 7415 -
Co
Cop py
VAG 1523A- or Tube
t. rig
gh ht
yri
cutter - VAS 6254- at a p by
o Vo
by c lksw
right angle ⇒ page 189 Prote
cted AG.
agen
188 Rep. gr.26 - Exhaust system

Separation point on the exhaust tube

– Cut exhaust tube in right angle on the -arrow 2-separation
point.
– Apply Sealant for exhaust connections - D 004 500- ⇒ See
Chemicals Manual. on the junctions; then, assemble the
sleeve and clamps on thegexhaust
en AG. V tube.
olkswagen AG
a does
lksw n
– Place double clamp db
y V for repair -4- during installationt gon
o o
ua lateral
identificationsori-arrow
se 1- and -arrow 3-. Tightening torque: ran
tee23
Nm. au
th or
a
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Install the double clamp so that the screw tip does not come
pe
ility
out beyond the lower edge of the double clamp itself.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
Support bearing position
com
tion in
r
– The distance -b- between the clamp and the exhaust pipe
te o
thi
support should be approx. 8 mm.

s
iva
do
r
rp
cum
– The -arrow- indicates the front of the vehicle.

fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

28 – Ignition system
1 Ignition system: repair AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
1.1 General instructions regarding the igni‐ or eo
h
aut ra
tion system ss c
ce
le
un
pt
an
♦ This chapter addresses especially ignition system related
d
itte
y li
components. Other injection and ignition system components
rm
ab
pe
⇒ page 155 .
ility
ot
wit
, is n
♦ A minimum voltage of 11.5V is necessary for the perfect op‐
h re
eration of electrical components.
hole
spec
es, in part or in w
♦ In some tests, the Engine control unit - J623- may detect and
t to the co
record a fault. Accordingly, once all tests and repairs are com‐
plete, check the event memory and erase it if necessary
⇒ page 182 .
rrectness of i
♦ If after troubleshooting, repair or component checking, the en‐
l purpos
gine starts for a moment and then dies right away, the Immo‐
bilizer control unit - J362- may be blocking the Engine control
unit - J623- . In this case, check the event memory and, if nec‐
nform
ercia
essary, adjust the Engine control unit - J623- ⇒ page 182 .

m
a
com
t
Safety measures ⇒ page 191 .
ion in
r
te o
Checking data, spark plugs ⇒ page 192 .
thi
s
iva
do
r
1.2 Ignition system components - remove

rp
cum
fo
en
g
and install
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
Note
by lksw
cted agen
Prote AG.
Engine control unit - J623- ⇒ Item 9 (page 159) .
190 Rep. gr.28 - Ignition system

1 - Connector
❑ Black, 4 poles.
❑ To the Ignition trans‐
former - N152- .
2 - Ignition transformer -
(N152)- AG. Volkswagen AG d
agen oes
ksw
❑ Installation location byV
ol not
gu
ara
⇒ page 155 . rised
nte
ho eo
❑ With codes for Spark aut ra
c
plug - Q- cables: A = cyl‐ ss
ce
e
inder 1 B = cylinder 3 C
nl
pt
du
an
= cylinder 2 D = cylinder
itte
y li
4
erm
ab
ility
ot p
3 - 10 Nm
wit
, is n
h re
4 - Connector
hole
spec
❑ Black, 2 poles.
es, in part or in w
t to the co
❑ For Knock sensor 1 -
G61- .
❑ Gold plated contacts for
rrectness of i
sensor and connector.
l purpos

❑ Installation location
nf
ercia
⇒ page 155 .
orm
m
❑ Gold plated contacts for
atio
m
Knock sensor 1 - G61-

o
n in
or c
and connector.
thi
te
sd
iva
6 - 20 Nm
o
r
rp
cu
o
m
❑ Tightening the torque in‐
f
en
ng
t.
yi
fluences the operation
Co
op py
of the Knock Sensor 1 -
. C rig
ht ht
rig
G61- . py by
co Vo
by lksw
cted
7 - Connector
agen
Prote AG.
❑ Black, 3 poles.
❑ For Hall Sensor - G40- .
❑ Installation location ⇒ page 155 .
9 - Seal
10 - Spark plugs - Q- , 30 Nm
❑ Remove and install with Spark plug wrench - 3122B- .
❑ Type and inter-electrode gap ⇒ page 192 .
❑ To the Ignition transformer - N152- .
12 - Ignition cable
❑ With interference suppression and Spark plug - Q- connector.
❑ Resistance 4.8...7.2 kΩ.
1.3 Safety measures

Consider the following in order to avoid personal injury and/or
deterioration of the injection and ignition systems:
1. Ignition system: repair 191

♦ Do not touch or disconnect the ignition cables with the engine

running or starting.
♦ Loosen and connect injection and ignition system cables, in‐
cluding the measuring equipment cables, only with ignition off.
If during a test cycle, it is necessary to use test and measuring
equipment, consider the following:
♦ Always install test and measuring equipment on the back seat
and have them operated by a second mechanic.
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.
♦ If the engine is to be turned over at starting speed, without
starting: agen
AG. Volkswagen AG d
o w es n
olks ot g
– Disconnect the 4-pole connector
ed
by from the Ignition transformer
V ua
ran
- N152- -arrow- . ho
ris tee
t or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
Note
o
cial p
f inform

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
1.4 Test data, spark plugs
cop Vo
by lksw
cted agen
Prote AG.
Engine codes BAH/BLH/CFZA BJA/BPA CCRA CFZA

Firing sequence 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Spark plugs24) 25) 26)101/905609// or 101/905601/C/ or 101/905610//C or 101/905601/G27)
101/905608// 101/905617/A/ 101/905625//
Manufacturer BOSCH or NGK BOSCH or NGK BOSCH or NGK BOSCH
Manufacturer desig‐ FL7HTCOR or F6HER2. or ZFR 6 F5DER2 or
nation BKUR5ETC-10 P-G BKR7ESB
Inter-electrode gap max. 0.9... 1.1 mm max. 0.8...0.9 mm max. 0.8... 0.9 mm max. 0.8... 0.9 mm
Tightening torque 30 Nm 30 Nm 30 Nm 30 Nm
192 Rep. gr.28 - Ignition system

24) Current values and replacement intervals of the Spark plugs - Q- : ⇒ Exhaust
gas Test Folder
25) Remove and install Spark plugs - Q- using Spark plug wrench - 3122B- .
26) Remove and install the Spark plug connectors - P...- with the Assembly tool -
T10029-
27) Spark plug introduced aas of
n A04/2014.
G. Volkswagen AG d
lksw ge oes
not
o
byV gu
ara
ed
ris nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Ignition system: repair 193

GEAR

Uploaded by

Copyright:

Available Formats

GEAR

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GEAR

Uploaded by

Copyright:

Available Formats

Service

4 - Cyl. injection engine (1.6 l)

BJA BAH BPA BLH CCR

Service Department. Technical Information

All rights reserved.

Copyright © 2017 Volkswagen AG, Wolfsburg BRA5R007320

1.5 Engine and gearbox support set - align . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.6 Power-drive group supports, (torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Crankshaft and flywheel flanges - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1.6 Oil pressure switch F1 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.3 Cleaning rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

1.8 Fuel reservoir - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.2 Activated charcoal filter system components - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 in t

1 Injection system - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 General instructions regarding the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1.2 Muffler with supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.1 Engine number

Additionally, there is a sticker -arrow- containing the “engine co‐

1.2 Engine characteristics

flex) flex) tal flex) rol)

Production 10/2003 to 11/2003 to 10/2003 to 10/2004 to 04/2008 ► 11/2008 ►

11/2008 11/2010 10/2004 06/2008

Cylinder 1599 1599 1599 1599 1598 1598

(etha‐ rpm 5750 (76.0)/5750 (76.0)/5250

2 Rep. gr.00 - Technical data

10 – Removing and installing engine

Special tools and workshop

♦ Lifting tackle - 2024A-

♦ Mounting bracket - VW 540-

1. Engine - remove and install 3

♦ Torque Wrench - 40 to 200 Nm ( 1/2” drive) - VAG 1332-

4 Rep. gr.10 - Removing and installing engine

♦ Sealing plug kit (engine) - VAS 6122-

1. Engine - remove and install 5

♦ Pipe sealing tool - T10249-

1.1 Removal - recommendations

6 Rep. gr.10 - Removing and installing engine

– Remove the Battery - A- tray ⇒ Electrical equipment; Rep. gr.

Hot vapours may escape when the coolant reservoir is opened;

Fuel supply hose is under pressure. Wrap hose connections in

1. Engine - remove and install 7

gearbox (02T and 0AP); Rep. gr. 30 ; Clutch - command sys‐

– Disconnect the connectors of electrical harness of gear selec‐

– Loosen or disconnect the following components:

♦ Hose for Cold start valve - N17- on throttle housing.

8 Rep. gr.10 - Removing and installing engine

Until December 9, 2007

From December 10, 2007

Vehicles with air conditioning:

1. Engine - remove and install 9

from the engine's support -A- -arrows-.

Until December 9, 2007

From December 10, 2007

10 Rep. gr.10 - Removing and installing engine

– Remove the engine and gearbox