Volkswagen Fox (2004 year). Manual - part 15

Note

Valves then will lean against piston head.

– Pull off valve stem seals with Puller -3047 A- .

2.3.2

Installing

– Install the plastic sleeve -A- supplied in the respective valve

stem. This will prevent the new valve stem -B- from being

damaged.

– Insert the new valve stem seal in the Fitter -3129- .
– Lubricate the seal lip at valve stem and tighten it carefully on

the valve guide.

Fox 2004 ➤

2. Valve command - repair    

57

 

Special tools and workshop

equipment required
♦ Blocking device -T10051-
♦ Extractor -T10052-
♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

Nm (enc. 1/2") -VAG 1332-

♦ Seal -AMV 17400401-

2.4.1

Removal

– Remove Poly-V belt 

⇒ page 14

 .

– Remove timing belt 

⇒ page 41

 .

– Remove fastening screws of camshaft gear -1-.
– Remove hub camshaft gear.

Fox 2004 ➤

58

 

hub is separated from the tapered section of the camshaft.

Note

Hold puller with a spanner while doing the above operation.

– Remove the camshaft hub.
– Remove cylinder head cover.
– Remove injector drive arm shaft.

Note

First, loosen the outer securing bolts, then one bolt of each pair

of inner securing bolts, and lastly the other bolt of each pair.

– Remove auxiliary pump 

⇒ page 97

 .

– First, remove bearing caps 2 and 3. Then, loosen bearing caps

1 and 4 alternately and diagonally.

Note

Bearing cap 4 is identified as bearing cap 5.

2.4.2

Installation

Note

♦

When installing the camshaft, the cams for cylinder 1 should

point upwards.

♦

Do not interchange used bearing shells (mark them).

♦

When installing the camshaft, ensure the proper clip seating

on the bearing caps and cylinder head.

♦

Before installing bearing caps, ensure that cylinder head bolt

washers are fitted in the cylinder head.

– Lubricate contact surfaces of shell bearings.

Fox 2004 ➤

2. Valve command - repair    

59

 

– Install bearing caps 1 and 4, and also tighten to 8 Nm + 90°

(replace).

Note

♦

Bearing cap 4 is identified as bearing cap 5.

♦

Apply Sealant -AMV 17400401- to seal surfaces of bearing

caps 1 and 4, which are in contact with the cylinder head

♦

Bearing cap 4 must align flush with outer edge of cylinder

head, because otherwise leaks may develop at the auxiliary

pump.

– Install the camshaft seal.
– Fit injector drive arm shaft and tighten first one bolt of each of

the inner pairs, then the other bolt of each pair, and finally the

outer securing bolts, evenly and alternately until there is no

more play in bearing, and finally tighten to torque. Tightening

torque: 20 Nm + 90° (replace).

– Install the hube on camshaft.
– Tighten hub fastening screw -1-. Tightening torque: 100 Nm.
– Use Blocking device -T10051- .

– Install camshaft gear on the hub.

Note

Toothed segment -arrow- of camshaft shall be on the top.

– Align camshaft gear in central position on elongated holes.
– Tighten manually the fastening screws -1- of the camshaft

gear in order not to have play.

– Immobilise hub with Mandrel -3359- .
– Install and adjust timing belt 

⇒ page 41

 .

– Install auxiliary pump 

⇒ page 97

 .

Note

When new tappets have been installed, do not start the engine

for about 30 minutes. Hydraulic compensation elements must knit

together (otherwise, valves will knock pistons).

Fox 2004 ➤

60