Volkswagen Fox (2004 year). Manual - part 10

Cylinder head - remove and install

Check compression 

⇒ page 49

 .

Note

♦

When mounting a replacement head with the camshaft moun‐

ted, lubricate all the contact surfaces between tappets and

cams before installing the head cover.

♦

All bearing and running surfaces must be lubricated before

assembly.

♦

The plastic shims provided for protecting the open valves

should not be removed until immediately before fitting cylinder

head.

♦

When replacing head, the cooling liquid should be totally re‐

placed too.

WARNING

Always replace self-locking nuts and screws subject to angular

torque

Fox 2004 ➤

1. Cylinder head - remove and install    

37

 

❑ Before removing, mark

operation direction.

❑ Check wear.
❑ Do not bend.
❑ Remove, install, and ad‐

just 

⇒ page 41

 .

3 - 10 Nm
4 - 25 Nm
5 - 100 Nm
6 - Camshaft gear
7 - Pulley

❑ With engine phase sen‐

sor wheel.

❑ Use Counter-hold tool -

T10051- to loosen and

tighten.

❑ To remove, use the Pull‐

er -T10052- .

❑ Remove and install

⇒ page 58

 .

8 - Mechanical distribution rear

cover
9 - Sealing ring

❑ Replace if damaged.

10 - Hall Sensor -G40-

❑ To the camshaft posi‐

tion.

❑ To remove, remove

sealing ring.

11 - Cylinder head securing bolt

❑ Replace.
❑ Check the sequence when loosening or tightening 

⇒ page 46

 .

❑ Before installing, set washers in cylinder head.

12 - Pin 10 Nm

❑ To engine cover.

13 - Cylinder head cover

❑ With oil filler nozzle.
❑ Replace oil filling nozzle if cylinder head cover is damaged.
❑ Before installing, carefully clean the cylinder head sealing surface with a clean cloth.

14 - To turbocharger
15 - 10 Nm

❑ First hand tighten all bolts.
❑ Then tighten both top bolts and thereafter the remainder from the inside outwards, diagonally, according

to the specified tightening torque.

16 - Pressure regulating valve

❑ To crankcase vent.

Fox 2004 ➤

38

 

18 - Cover

❑ Replace seal if damaged.

19 - Gasket

❑ Replace if damaged.

20 - Support

❑ With fuel tube/hose.

21 - Cylinder head cover gasket

❑ Replace if damaged.

22 - 20 Nm
23 - Lifting eye
24 - Injection unit

❑ Remove and install 

⇒ page 112

 .

25 - Central connector

❑ To injector.

26 - From servo brake
27 - Tandem pump

❑ For supplying fuel and vacuum.
❑ Remove and install 

⇒ page 97

 .

❑ Check 

⇒ page 95

 .

28 - Supply hose

❑ From fuel filter 

⇒ Item 1 (page 87)

 .

❑ White or with white marking.
❑ Check that it is securely installed.
❑ Fasten with spring braces.

29 - Return hose

❑ To fuel filter 

⇒ Item 1 (page 87)

 .

❑ Blue or blue marked.
❑ Check that it is securely installed.
❑ Fasten with spring braces.

30 - Gasket

❑ Replace.

31 - Support
32 - Hexagonal nut
33 - Cylinder head

❑ Remove and install 

⇒ page 46

 .

❑ When replacing, renew the complete coolant.

34 - Cylinder head gasket

❑ Replace.
❑ Check marking 

⇒ page 40

❑ When replacing, renew the complete coolant.

35 - Glow plug

❑ 15 Nm.

Fox 2004 ➤

1. Cylinder head - remove and install    

39

 

Check the cylinder head for bending.
Max. permissible bending: 0.1 mm.

Note

Diesel engine head rework is not permitted.

Identification of cylinder head gasket
♦ Part number = -arrow 1-.
♦ Production control code = -arrow 2- (can be disregarded).
♦ Holes = -arrow 3-.

Note

Different cylinder head gasket thicknesses are mounted, depend‐

ing on the piston projection. When replacing the cylinder head

gasket, install a new part with the same identification.

Fox 2004 ➤

40