Volkswagen Fox (2004 year). Manual — part 3
Engine - dismantle and assemble
Note
♦
Where large quantities of metal shavings and filings are de‐
tected in the engine oil during repair required as a result of
crankshaft and connecting rod bearing wear, the oil filter must
be replaced and the oil channels carefully cleaned.
♦
All bearing and running surfaces must be lubricated before
assembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
1. Engine - dismantle and assemble
9
II
⇒ page 11
III
⇒ page 12
Part I
1 - Timing belt guard - upper
part
2 - Timing belt
❑ Mark rotation direction
before removal.
❑ Check wear.
❑ Do not bend.
❑ Remove, install, and ad‐
just
⇒ page 41
.
3 - 20 Nm +45°
❑ Replace after each
remova.l
4 - Timing belt tension pulley
5 - 100 Nm
6 - 25 Nm
7 - Camshaft gear
8 - Pulley
❑ Engine speed sensor.
❑ Immobilise with Coun‐
ter-hold tool -T10051- to
loosen or tighten.
❑ To remove, use Extrac‐
tor -T10052- .
❑ Remove and install
⇒ page 58
.
9 - 10 Nm
10 - Mechanical distribution
rear cover
11 - Sealing ring
❑ Replace if damaged.
12 - Pulley
13 - Water pump
❑ Remove and install
⇒ page 80
.
14 - Crankshaft gear
15 - 120 Nm + 90°
❑ Replace after each removal..
❑ Immobilise with Lock -3415- to loosen or tighten.
❑ Do not apply additional oil or grease to the threads and recess/flanges.
❑ The angular torque can be performed in several stages.
Fox 2004 ➤
10
20 - 10 Nm + 90°
❑ Replace after each removal.
21 - Timing belt guard - centre part
Part II
1 - Cylinder head cover
❑ With oil filler nozzle.
❑ Replace oil filling nozzle
if cylinder head cover is
damaged.
❑ Before installation,
carefully clean the cylin‐
der head sealing sur‐
face with a clean cloth.
2 - To turbocharger
3 - 10 Nm
❑ First, hand tighten all
bolts.
❑ Then, tighten both top
and remaining bolts
from the inside out, di‐
agonally, to specified
tightening torque.
4 - Pressure regulating valve
❑ To crankcase vent.
5 - Cover
❑ Replace seal if dam‐
aged.
6 - Gasket
❑ Replace if damaged.
7 - Oil filling nozzle
❑ Replace.
8 - Engine and gearbox sup‐
port
❑ With fuel tube.
9 - Cylinder head cover gasket
❑ Replace if damaged.
10 - 20 Nm
11 - Lifting eye
12 - 10 Nm
13 - Central connector
❑ To injector
14 - From servo brake
Fox 2004 ➤
1. Engine - dismantle and assemble
11
⇒ page 97
.
❑ Check
⇒ page 95
.
16 - 25 Nm
17 - Supply hose
❑ From fuel filter
⇒ Item 1 (page 87)
.
❑ White or with white marking.
❑ Check that it is securely installed.
❑ Fasten with spring braces.
18 - Return hose
❑ To fuel filter
⇒ Item 1 (page 87)
.
❑ Blue or blue marked.
❑ Check that it is securely installed.
❑ Fasten with spring braces.
19 - Gasket
❑ Replace.
20 - Pin 10 Nm
❑ To engine cover.
21 - Engine and gearbox support
22 - Hexagonal nut
23 - Cylinder head gasket
❑ Replace.
❑ Observe identification
⇒ page 35
.
❑ When replacing, use completely new coolant.
24 - Hall Sensor -G40-
❑ To the camshaft position.
❑ Loosen to remove sealing ring from the mechanical distribution rear cover.
25 - Cylinder head securing bolt
❑ Replace.
❑ Follow the installation and removal sequence
⇒ page 46
.
❑ Insert washers into cylinder head before installing.
26 - Injectors
❑ Remove and install
⇒ page 112
.
Part III
WARNING
Always replace self-locking nuts and screws subject to angular
torque
Fox 2004 ➤
12
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