Volkswagen Fox (2004 year). Manual - part 12

gine rotation until the Crankshaft stop -T10050- is positioned

in front of the hole at sealing flange -arrow-

– Now, turn the crankshaft in the engine rotation direction until

the crankshaft stop pin locks in the sealing flange while turn‐

ing.

– Tighten fastening screws of the camshaft gear to 25 Nm.
– Remove mandrel -3359- and Crankshaft stop -T10050- .
– Turn crankshaft twice in the engine turn direction until it is in

the TDC of cylinder 1 again.

Note

♦

When doing this, the crankshaft stop end shall engage in the

sealing flange while turning the engine.

♦

When the crankshaft is turned beyond the TDC of cylinder 1

and the crankshaft stop is not engaged in the sealing flange,

turn the crankshaft 

1

/4turn in the reverse direction in order to

readjust TDC of cylinder 1. No correction is allowed while the

engine is turning, so as to ensure the correct operation of the

crankshaft stop.

– Repeat checking.
– Install the lower cover of the mechanical distribution and the

vibration absorber.

– Install mechanical distribution centre cover.
– Install mechanical distribution upper cover.
– Install engine support and console. Torque setting 

⇒ page 8

 .

– Install Poly-V belt 

⇒ page 14

 .

– Install the hoses between intercooler and turbocharger, and

between intercooler and intake connecting flange.

Fox 2004 ➤

1. Cylinder head - remove and install    

45

 

Special tools and workshop

equipment required
♦ Support -10-222A-
♦ Support -T10014-
♦ Tray -VAG 1306-
♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

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

♦ Vacuum pump -

V.A.G 1390-

♦ Fluid receptacle -V.A.G 1390/1-

1.2.1

Removal

– Remove timing belt 

⇒ page 41

 .

Fox 2004 ➤

46

 

tional support should be fastened to the engine block for removing

the cylinder head.

– Fit Support bracket -10-222A- as shown and support the en‐

gine in its installation position.

– Carefully lift the engine slightly with spindle -A-.

– Attach Retainer -T10014- to engine block using the threaded

hole in the vicinity of water pump, as illustrated. Tightening

torque: 20 Nm.

– Lift engine slightly using second spindle -B- until spindle -A- is

relieved.

– Remove spindle -A-.
– Before removing cylinder head, drain fuel at auxiliary pump

using Manual vacuum pump -V.A.G 1390- with the Fluid re‐

ceptacle -V.A.G 1390/1- 

⇒ page 97

 .

– Follow the sequence indicated when loosening or tightening

the cylinder head screws.

Fox 2004 ➤

1. Cylinder head - remove and install    

47

 

Note

♦

Always replace head screws.

♦

In cases of repair, carefully remove gasket remains from cyl‐

inder head and engine block. Ensure that no long grooves or

scratches are created. When using sand paper, do not use

less than 100 grade.

♦

Carefully remove emery and abrasive remains.

♦

Only remove new cylinder head gasket from packaging prior

to installation.

♦

Handle gasket extremely carefully. Damage to the silicone

layer or the indented area will cause leakage.

– Turn the crankcase to the TDC marking before installing the

cylinder head.

– Turn crankshaft in the opposite direction of engine rotation

until all the pistons are approximately equally placed below

TDC.

– Place head gasket.
– Fit cylinder head and hand tighten all its bolts.
– Tighten the cylinder head in four stages, as follows:
– 1. Previous tightening with torque meter:

1st stage (torque)

40 Nm

2nd stage (torque)

60 Nm

– 2. Tighten with normal spanner:

3rd stage (angular torque)

90°

4th stage (angular torque)

90°

Note

No retightening of the cylinder head is required after repairs.

– After tightening the cylinder head, turn the camshaft so that all

the cams in cylinder 1 are turned equally upwards. Before

mounting the cylinder head, turn the crankshaft in the engine

rotation direction until TDC 

⇒ page 41

 .

– Perform test drive and check fault memory 

⇒ page 115

 .

Fox 2004 ➤

48