Get Supplysystem-fuelinjection -> 1 Injection system - repair Guide for Volkswagen Fox SUV Second Generation (2003-2021)

lk

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

24 – Supply system - fuel injection

1

Injection system - repair

General indications about the injection system

♦ The Engine control unit -J623- is equipped with self-diagnosis.

Before carrying out repairs and troubleshooting, always check

the fault memory first. Likewise, check vacuum hoses and

connections (air infiltration).

♦ Minimum voltage of 11.5V is necessary for the perfect opera‐

tion of electric components.

♦ Do not use sealants with silicone. Silicone component resi‐

dues aspired by the engine are not burned and damage the

Lambda Probe -G39- .

♦ Vehicles with airbag have a system for shutting off fuel in case

of an accident. This system should prevent fire in the vehicle

after an accident by disconnecting the Fuel pump (pre-supply

pump) -G6- through the Fuel pump relay -J17- . At the same

time, with this equipment, the engine starts more smoothly.

Fuel injection components - remove and install ⇒ page 87 .

Intake manifold - remove and install ⇒ page 89 .

Fuel distributor with injection valves - remove and install

⇒ page 90 .

Air filter set - disassemble and assemble ⇒ page 90 .

Air filter set - remove and install ⇒ page 91 .

Safety measures ⇒ page 92 .

Cleaning rules ⇒ page 65 .

Technical data ⇒ page 94 .

1. Injection system - repair

85

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.1

Component location

A - Brake pedal switch -F47- or

Brake light switch -F-

lk

❑ Together in one case, in

the feet compartment,

on the brake pedal.

B - Accelerator pedal position

sensor -G79- and Sensor 2 of

accelerator pedal position -

G185-

❑ At the feet compart‐

ment, on the accelerator

pedal.

C - Clutch pedal switch -F36-

❑ In feet compartment, on

clutch pedal.

D - Fuel pressure regulator

❑ On the Fuel pump (pre-

supply pump) -G6- .

1 - Magnetic valve 1 for activa‐

ted charcoal filter tank -N80-

❑ In the engine compart‐

ment.

2 - Intake manifold

❑ Remove and install.

3 - Knock sensor 1 -G61-

❑ Installation location: On

engine block, intake

side.

4 - Engine control unit -J623-

❑ Below the lower wind‐

screen coating.

❑ Remove and install.

5 - Engine speed sensor -G28-

❑ Installation location: On engine block, intake side.

6 - Air intake temperature sensor -G42- with the Intake manifold pressure sensor -G71-

7 - Aeration hose valve

8 - Accelerator butterfly valve control unit -J338-

9 - Hall Sensor -G40-

10 - Coolant temperature sensor -G62-

11 - Air Filter

❑ Remove and install ⇒ page 91 .

12 - Oil pressure switch -F1-

13 - Lambda probe after the catalytic converter -G130-

14 - 4-pin connector

❑ Black

❑ To the Lambda probe -G39- Lambda probe heating -Z19- .

86

Rep. Gr.24 - Supply system - fuel injection

lk

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

15 - Lambda probe -G39-

16 - Ignition coil 1 with final power stage -N70- , Ignition coil 2 with final power stage -N127- and Ignition coil 3

with final power stage -N291-

17 - Fuel distributor

18 - Cylinder 1 injector - N30- , Cylinder 2 injector -N31- and Cylinder 3 injector -N32-

1.2

Fuel injection components - remove and install

1 - Air filter set

❑ With filtering element.

❑ Disassemble and as‐

semble ⇒ page 90 .

❑ Remove and install

⇒ page 91 .

2 - Duct for air aspiration

3 - Injection valve harnesses.

4 - Connector

❑ Black, 2 poles

❑ From Cylinder 1 injec‐

tion valve -N30 - .

❑ From Cylinder 2 injec‐

tion valve - N31- .

❑ From Cylinder 3 injec‐

tion valve - N32- .

5 - 10 Nm

6 - Fuel distributor with injec‐

tion valves

❑ Remove and install

⇒ page 90 .

7 - 20 Nm

8 - 20 Nm

9 - Intake manifold

10 - Lambda probe -G39- , 50

Nm

❑ Lubricate only the

thread with High-tem‐

perature paste -G 052

112 A3- ; High-tempera‐

ture paste -G 052 112

A3- should not enter in the grooves on the Lambda probe -G39- body.

❑ Remove and install with the Socket set for Lambda probe -3337- .

11 - Connector

❑ Black, 4 poles.

❑ From Lambda probe -G39- .

12 - 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- should not enter in the grooves on the Lambda probe -G130- body, after the catalytic converter.

❑ Remove and install with the Socket set for Lambda probe -3337- .

13 - Connector

❑ Black, 4 poles.

1. Injection system - repair

87

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

❑ From Lambda probe after catalytic converter -G130 - .

14 - 10 Nm

15 - Coolant temperature sensor -G62-

❑ Before removing, eliminate, if necessary, cooling system pressure.

❑ 2-pole connector.

16 - Sealing ring

❑ Replace if damaged

17 - Retaining clip

❑ Check for proper seating.

18 - 10 Nm

19 - Thermostat valve body

lk

20 - Retaining clip

❑ Check for proper seating.

21 - Coupling connector

❑ Connect or disconnect the connector with ignition switched off.

22 - Engine control unit -J623-

❑ In case of replacement, it is necessary to adapt the Engine control unit -J623- to the Immobiliser control

unit -J362- ⇒ Vehicle diagnosis, testing and information system VAS 5051.

23 - Spring clamp

24 - Air duct

25 - From head cover

88

Rep. Gr.24 - Supply system - fuel injection

lk

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.3

Intake manifold - remove and install

1 - 10 Nm

2 - Butterfly valve command

unit - J338-

❑ 6-pole coupling connec‐

tor.

❑ Golden contacts.

❑ Warmed Coolant.

❑ In case of replacement,

adapt the Engine control

unit -J623- to the Butter‐

fly valve command unit -

J338- ⇒ Vehicle diagno‐

sis, testing and informa‐

tion system VAS 5051.

3 - Gasket

❑ Replace.

4 - Coupling nozzle

❑ For oil separator.

5 - Coupling nozzle

❑ For the Electromagnetic

valve 1 for activated

charcoal filter -N80- .

6 - Sealing ring

❑ Replace if damaged

7 - 20 Nm

8 - 3 Nm

9 - Intake manifold pressure

sensor -G71- with Air temper‐

ature sensor -G42-

❑ 4-pole coupling connec‐

tor.

❑ Golden contacts.

10 - Sealing ring

❑ Replace if damaged

11 - 20 Nm

12 - Sealing ring

❑ Replace if damaged

13 - Intake manifold

14 - Intake nozzle

1. Injection system - repair

89

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.4

Fuel distributor with injection valves - remove and install

1 - Fuel distributor with injec‐

tion valves

❑ Check injection valves

for tightness and flow

⇒ page 95 .

2 - Sealing ring

❑ Replace.

❑ Quickly lubricate with

engine clean oil before

installation.

3 - For cylinder 1 injection

valve -N30 -

❑ For cylinder 2 injection

valve -N31- .

lk

❑ For cylinder 3 injection

valve -N32- .

❑ Check injection valves

for tightness and flow

⇒ page 95 .

4 - Retaining clip

❑ Ensure proper seating

on injection valve and

fuel distributor.

5 - Drainage valve

❑ Drain the air

⇒ page 78 .

6 - 10 Nm

1.5

Air filter set - disassemble and assemble

Note

♦ For fastening the upper part of the air filter to the lower part, a

number of self-tightening bolts are used. If these bolts are

tightened or loosened with a power screwdriver, the thread on

the lower part of the filter can be damaged.

♦ For that reason, a power screwdriver is allowed only if:

♦ the power screwdriver speed does not exceed 200 rpm

♦ a torque of 1.6 Nm at most is adjusted.

90

Rep. Gr.24 - Supply system - fuel injection

Supplysystem-fuelinjection -> 1 Injection system - repair for Your Volkswagen Fox SUV Second Generation (2003-2021)

Related Topics

Popular Owner Manuals

Latest Owner Manuals