Volkswagen Fox (2004 year). Manual - part 28

♦ Follow cleanliness rules 

⇒ page 88

 .

♦ Always replace retainers and sealing rings.

WARNING

Always replace self-locking nuts and screws subject to angular

torque

1 - 20 Nm + 90°

❑ Replace after each re‐

moval.

2 - Rocker arm shaft

❑ With rocker arm.
❑ Remove and install

⇒ page 112

 .

3 - Self-locking nut
4 - Set screw

❑ Replace.

5 - Ball head pin

❑ Replace.

6 - Injectors

❑ Remove and install

⇒ page 112

 .

7 - Sealing ring

❑ Replace 

⇒ page 109

 .

8 - Sealing ring

❑ Replace 

⇒ page 109

 .

9 - Sealing ring

❑ Replace 

⇒ page 109

 .

10 - Heat insulation sealing

❑ Replace.

11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - 12 Nm +270°

❑ Replace after each re‐

moval.

1.6

Sealing ring for injectors - remove and

install

Special tools and workshop equipment required

Fox 2004 ➤

1. Maintaining the direct injection Diesel system    

109

 

Removal

– Remove carefully old rings from injector.
– Ensure that no burrs are formed on the ring seat in the oper‐

ation above.

1.6.2

Installation

Note

♦

Always use the assembly sleeves to fit the rings. If the as‐

sembly sleeves are not used, the rings may be damaged.

♦

Gradually introduce the rings with no coloured markings. Then

check that the rings are correctly positioned in their respective

grooves. Ring size decreases towards nozzle.

♦

Prevent the rings from rolling when sliding them on. The rings

must not be twisted when seated on the injector.

– Pull the heat insulation cover with the fastening clip.
– Carefully clean the seating surfaces of the injector ring.
– Slide Assembly sleeve -T10056/1- to stop position on unit in‐

jector.

– Slide upper ring carefully towards assembly sleeve and into

injector seat.

– Remove assembly sleeve.

Fox 2004 ➤

110

 

– Slide intermediate ring carefully towards assembly sleeve and

into injector seat.

– Remove assembly sleeve.

– Slide Assembly sleeve -T10056/3- to stop position on unit in‐

jector.

– Slide lower ring carefully towards assembly sleeve and into

injector seat.

– Remove assembly sleeve.
– Install the heat insulation cover with the fastening clip.

Fox 2004 ➤

1. Maintaining the direct injection Diesel system    

111

 

Special tools and workshop

equipment required
♦ Support -VW 387-
♦ Multi-tooth Socket -3410-
♦ Special wrench, long reach

-T10054-

♦ Extractor -T10055-
♦ Torque wrench - 5 to 50 Nm

(enc. 1/2") -VAG 1331-

1.7.1

Removal

– Remove the upper cover of the mechanical distribution and

the cylinder head cover.

– Turn crankshaft until the cams of the injector to be removed

point upwards.

– Loosen self-locking nuts of set screws -1- and remove the

screws.

– Remove rocker arm securing bolts -2- (from outwards to in‐

wards) with Multi-tooth socket -3410- and remove rocker arm

shaft.

– Remove tensioning block securing bolts -3- with Special long

reach wrench, -T10054- , and remove the block.

– Remove injector connector by using a screwdriver. To avoid

inclination, support opposite side of connector with light finger

pressure.

– Check injector locations.

Fox 2004 ➤

112