Volkswagen Fox (2004 year). Manual — part 7
Special tools and workshop
equipment required
♦ Pin -T10060-
♦ Multi-point spanner -
T10061-
♦ Torque wrench - 5 to 50 Nm
(enc. 1/2") -VAG 1331-
♦ Torque wrench - 40 to 200
Nm (enc. 1/2") -VAG 1332-
♦ Spanner (24/27 mm AF)
3.1.1
Removal
– Remove Poly-V belt
⇒ page 14
.
– Remove timing belt
⇒ page 41
.
– Remove crankcase
⇒ page 68
.
– Remove sealing flange, pulley side
⇒ page 17
.
– Remove cover securing bolts.
– Remove cover from mounting frame.
Fox 2004 ➤
3. Counterbalance shaft and retaining frame - remove and install
25
– Loosen the gear -1- from mounting frame.
– Remove securing bolt --2-- from chain tensioning element and
remove it.
– Remove the chain and put it on a clean surface.
– Immobilise counterbalance shaft, as shown, with a Spanner
(24/27 mm AF) -1-.
Note
When immobilizing the counterbalance shaft, make sure that the
spanner is centred on the counterbalance and at right angles to
counterbalance shaft.
– Loosen fastening bolt -2- of the counterbalance.
Note
Only loosen the fastening bolt -2- of the counterbalance; do not
remove.
– Unbolt mounting frame --3-- from engine block and remove it
with counterbalance shaft.
– Put the mounting frame on a clean surface.
– Remove counterbalance securing bolts.
– Remove counterbalance and counterbalance shaft gear.
– Turn the counterbalance shaft so that it can be removed from
the bearing.
3.1.2
Installing
– Sliding surfaces of the bearing oil.
– Set counterbalance shaft in bearing.
– Fit the gear and counterbalance on counterbalance shaft.
Note
Installing the gear and counterbalance is only possible in a single
position.
– Hand tighten securing bolt for counterbalance weight and
gear.
– Tighten mounting frame to engine block by hand so that there
is no play.
Fox 2004 ➤
26
When positioning the frame, make sure that the fastening
guide is inserted into the engine block and the O-ring is fitted
in the mounting frame.
♦
Align the mounting frame so that it fits flush with the outer edge
of the engine block on the pulley end.
– Bolt mounting frame with counterbalance shaft to engine
block. Tightening torque: 20 Nm.
– Check that mounting frame aligns flush with outer edge of en‐
gine block on the pulley end.
– Immobilise counterbalance shaft, as shown, with a Spanner
(24/27 mm AF) -1-.
Note
When immobilizing the counterbalance shaft, make sure that the
spanner is centred on the counterbalance and at right angles to
counterbalance shaft.
– Tighten fastening bolt -2- of the counterbalance. Tightening
torque: 100 Nm +90°.
Note
The fastening bolt is a tensioning bolt and must always be re‐
placed.
– Install chain tensioning element. Tightening torque: 8 Nm +
90°.
Note
The fastening bolts of the chain tensioning element are tensioning
bolts and must always be replaced.
– Clean chain with a lint-free cloth.
– Ensure that mark on crankshaft sprocket -arrow- is at top.
Fox 2004 ➤
3. Counterbalance shaft and retaining frame - remove and install
27
the crankshaft sprocket and counterbalance sprocket align
with the colour-coded chain links -arrows-.
Note
The colour-coded chain links are marked with a notch.
– Fit the free sprocket in the chain and tighten the free sprocket
to the mounting frame. Tightening torque: 20 Nm.
– Remove Locking pin -T10060- from chain tensioning element.
– Make sure that the marks on the crankshaft sprocket and
counterbalance shaft sprocket align with the colour-coded
chain links -arrows-.
Note
The colour-coded chain links are marked with a notch.
– Install pulley end sealing flange
⇒ page 17
.
– Install counterbalance shaft cover. Tightening torque: 5 Nm.
Note
♦
Before installing cover, lubricate O-ring of oil pump, as well as
shaft on inside of cover
♦
Make sure of the proper seating of sealing strip in cover.
♦
When installing cover, ensure that cover engages in mounting
frame.
– Install crankcase
⇒ page 68
.
– Install and adjust timing belt
⇒ page 41
.
– Install Poly-V belt
⇒ page 14
.
Fox 2004 ➤
28
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