Volkswagen Fox (2004 year). Manual - part 26

Overcharge system with turbocharg‐

er

1.1

Safety measures

WARNING

During assembly work, especially within the engine compart‐

ment, due to the lack of space, bear in mind the following :

♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter

system, cooling system and cooling gas, brake fluid, vac‐

uum) and electric cables must be restored to original

positions.

♦ To provide easy access to all the moving or hot parts.

If during a test drive it is necessary to use test and measuring

equipment, observe the following:
♦ Always install test and measuring equipment on the back seat

to be operated by someone from there.

If test and measuring equipment are operated from the passenger

seat, the person seated there may be injured should the airbag

activate in case of accident.

1.2

Cleanliness rules

When working on the overcharge system, pay careful attention to

the following cleanliness rules :
♦ Carefully clean all the connections and surrounding areas be‐

fore disconnecting them.

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

Do not use cloth that releases lint!

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

components should be covered up or carefully preserved.

♦ Install only clean components. Only remove spare parts from

packaging just prior to installing them. Do not install compo‐

nents that have been kept out of packaging (i.e. inside the tool

box, etc.).

♦ During repair services, remove oil from hose connections and

ends.

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

possible, do not move the vehicle.

1.3

Turbocharger - remove and install

Follow safety measures 

⇒ page 101

 .

Follow cleanliness rules 

⇒ page 101

 .

Fox 2004 ➤

1. Overcharge system with turbocharger    

101

 

All the hoses are fastened with clamps or coupling fittings.

♦

When installing spring clamps, use Standart-type clamp pliers

-VAS 5024A- .

♦

Do not install hoses containing lubricant on its connections.

♦

Overcharge system must be free of leaks.

♦

Before installing the oil supply pipe, fill the turbocharger,

through the connection point, with engine oil.

♦

After installing the turbocharger, run the engine during at idle

speed for about 1 minute. Do not accelerate the engine. This

will ensure the turbocharger is properly lubricated.

♦

Always replace self-locking nuts.

Hoses with coupling connections

Note

All the overcharge system hoses are fastened with spring clamps

or connections. Always check the following points in the connec‐

tions:

– Release the connection by pulling the fixing clip -arrow-, with‐

out using tools.

– When assembling, make sure the retaining tabs -A- are firmly

secured.

Fox 2004 ➤

102

 

haust gases.

❑ Full replacement only.
❑ To remove, first remove

the hose between the

turbocharger/air mass

meter, intake manifold/

intercooler hose, input

flange with exhaust gas

recirculation valve, and

the intake manifold

valve motor, as well as

the drive shaft right cov‐

er.

2 - Intake manifold
3 - From the intercooler
4 - Gasket

❑ Replace.
❑ Covering (fillet) towards

the intake manifold.

5 - 25 Nm
6 - Gasket

❑ Check installation posi‐

tion.

7 - From the air filter
8 - Support

❑ From heat deflector.

9 - Washer
10 - 25 Nm
11 - Heat deflector

❑ Fasten on the bracket

12 - Hollow screw, 15 Nm
13 - Packing

❑ Replace.

14 - Hose

❑ To Electromagnetic valve for limiting charge pressure -N75- .

15 - Oil return pipe, 30 Nm

❑ To engine block.

16 - 15 Nm
17 - Gasket

❑ Replace.

18 - Front exhaust pipe
19 - 25 Nm

❑ Replace.

20 - Connection, 30 Nm

❑ Replace.
❑ Apply -G 052 112 A3- on the threads and contact surface of the screw head.
❑ Fill turbocharger with engine oil before installing the oil supply tube.

Fox 2004 ➤

1. Overcharge system with turbocharger    

103

 

⇒ page 65

 .

22 - 10 Nm
23 - Support

1.4

Intake air cooling system (intercooler)

components - remove and install

Note

♦

All the hoses are fastened by clamps.

♦

When required, use sliding agent (water without additive). Do

not use sliding agents containing oil.

♦

When repairing, remove oil from the hose connections and

ends.

♦

Overcharge system must be free of leaks.

Fox 2004 ➤

104