Get Crankshaft,pistons Guide for Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

13 – Crankshaft, pistons

1

Engine - disassemble and assemble

For disassembling works, the engine must be fastened to the

Support -VW 540- or Rotary stand for engine and transmission -

VAS 6095- .

Part I - Operating the belt ⇒ page 11 .

Part II - Operating the chain ⇒ page 11 .

Remove and install Poly-V belt ⇒ page 13 .

Remove and install control box ⇒ page 15 .

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Caution

Crankshaft cannot be removed. Simply loosen crankshaft

bearing cover bolts for the engine block bearing shells not to

be deformed. Such deformation reduces bearing shells clear‐

ance. Even if bearing shells are not replaced, there can be

damages due to change in the clearance.

If bearing cover bolts are loosened, the entire engine block with

the crankshaft will have to be replaced.

The workshop does not have the necessary means to measure

the crankshaft radial clearance.

WARNING

Always replace self-locking nuts and screws subject to angular

torque

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Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.1

Part I - Operating Poly-V belt

1 - 20 Nm

2 - Pulley

❑ For water pump.

3 - Cover

4 - Poly-V belt tensioning pul‐

ley

5 - 20 Nm + 90°

❑ Replace after each re‐

moval.

6 - Alternator

7 - Return pulley

8 - Washer

9 - Pulley

❑ From the crankshaft.

10 - 90 Nm + 90°

❑ Replace after each re‐

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moval.

11 - Guide bushing

12 - 25 Nm

13 - Guide bushing

14 - Spacer sleeve

15 - Poly-V belt

❑ Mark rotation direction

before removal.

❑ Remove and install

Poly-V belt

⇒ page 13 .

1.2

Part II - Operating the chain

WARNING

Always replace self-locking nuts and screws subject to angular

torque

1. Engine - disassemble and assemble

11

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1 - Cylinder head cover

❑ Sealing surface cannot

be ground.

❑ With integrated cam‐

shaft bearings.

❑ Remove residues from

the old Sealing putty for

engines -AMV 188 001

02- .

❑ Before installation, ap‐

ply a coat of Sealing put‐

ty for engines -AMV 188

001 02- .

❑ For installation, put it in

the vertical position,

from up to down, with

the adjusting pins into

the cylinder head holes.

2 - Engine block

❑ 2 parts.

❑ The screws cannot be

loosened.

3 - Gear

❑ From the crankshaft.

4 - Gear

❑ From balancing shaft.

❑ Fastening screw cannot

be loosened.

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5 - Chain stretcher with ten‐

sioning chute

❑ From roller chain

⇒ Item 10 (page 12) .

6 - Oil pump

❑ Replace only the complete set.

7 - Sliding chute

❑ From roller chain ⇒ Item 33 (page 13) .

8 - Gear

❑ From the crankshaft.

9 - Gear

❑ From oil pump activation.

10 - Roller chain

❑ Mark rotation direction before removal (installation positions).

11 - Gear

❑ From oil pump.

❑ After installation, adjust distribution times ⇒ page 32 .

12 - Crankcase

❑ Remove and install in engines with liquid joint ⇒ page 48 .

❑ Clean the Engine silicone sealant -D 176 404 A2- from the surface before installing.

❑ Install with Engine silicone sealant -D 176 404 A2- .

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Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

13 - 15 Nm

14 - 8 Nm

15 - Cover

16 - 20 Nm + 90°

❑ Replace after each removal.

17 - Crankshaft pulley

❑ Remove and install Poly-V belt ⇒ page 13 .

18 - 90 Nm + 90°

❑ Replace after each removal..

❑ Fit lubricated.

❑ Immobilise crankshaft pulley with the Spanner -3415- .

❑ The additional angle torque can be measured with a spanner, e.g. Hazet 6690.

19 - Supporting bushing

20 - 25 Nm

21 - 45 Nm

22 - 10 Nm

23 - 10 Nm

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24 - To intake manifold

25 - Oil separator

❑ With depression valve.

26 - Sealing ring

❑ Replace if damaged

27 - Control box

❑ Install with Engine silicone sealant -D 176 404 A2- .

❑ For better alignment in assembly, install two vertical bolts -M6x75- into the cylinder head and engine

block.

❑ For better alignment of the control box, install oil crankcase with two bolts.

28 - Cover

29 - 20 Nm + 90°

❑ Replace after each removal.

30 - Tensioning chute

31 - Chain stretcher

32 - 15 Nm

33 - Roller chain

34 - Gear

❑ From Camshaft

❑ Immobilise the gear with the Special wrench -3036 - .

35 - Guide pin

❑ Tightening torque: 20 Nm

1.3

Poly-V belt - remove and install

Special tools and workshop equipment required

1. Engine - disassemble and assemble

13

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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ Hexagonal wrench -3449-

Operation sequence

– Mark the Poly-V belt turning direction.

– Move tensioning element in the arrow direction, until the hole

is visible. Retain tensioning element with an Hexagonal

wrench -3449- .

– Move the tensioning element towards -arrow- with socket and

spanner. Secure the tensioning element with a Hexagonal

wrench -3449- .

– Remove or install Poly-V belt .

Note

When installing Poly-V belt, ensure the proper seating of the belt

on the pulleys.

Poly-V belt travel

Belt operation without ar conditioning compressor

1 - Water pump pulley

2 - Tensioning pulley

3 - Generator (Alternator) -C- pulley

4 - Poly-V belt

5 - Crankshaft pulley

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Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Belt operation with ar conditioning compressor

1 - Water pump pulley

2 - Tensioning pulley

3 - Generator (Alternator) -C- pulley

4 - Pulley

5 - Air conditioning compressor pulley

6 - Poly-V belt

7 - Crankshaft pulley

The rest of the installation is carried out in removal reverse order.

1.4

Control box - remove and install

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Special tools and workshop

equipment required

♦ Support or 10-222A -VW

061-

♦ Hooks -10-222A/10-

♦ Wrench -3415-

♦ Pins -3415/1-

♦ Torque wrench - 5 to 50 Nm

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

1. Engine - disassemble and assemble

15

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ Torque wrench - 40 to 200 Nm (enc. 1/2") -VAG 1332-

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1.4.1

Removal

– Remove the front right wheel case protector: ⇒ Body - Exter‐

nal assembly repairs; Rep. Gr. 66 ; External equipment .

– Mark the Poly-V belt operating direction and remove it

⇒ page 13 .

– Remove air conditioning compressor from support with pipes

connected: ⇒ Heating - ventilation ; Rep. Gr. 87 ; Air condi‐

tioning .

– Remove Generator (Alternator) -C- .

– Install Support -10-222 A- with Rack -10 - 222 A /1- , as illus‐

trated, and install on lifting eye-arrow-.

– Pre-tension the engine slightly and loosen fastening bolts

-arrows-.

– Remove oil crankcase ⇒ page 48 .

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Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove the fastening bolts from the crankshaft pulley. Immo‐

bilise the pulley with the Spanner -3415- and -3415/1- .

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– Remove fastening bolts from control box and bolts designated

by the -arrows-.

– Remove control box.

Note

Ensure that the crankshaft support pin remains on sealing flange.

1.4.2

Installation

– Clean sealing surfaces thoroughly. They must be free from oil

and grease.

– Seat the new gasket on adjusting pin.

– To facilitate alignement, install two Bolts -M6x80- on cylinder

head and engine block.

– Install control box and crankshaft support, simultaneously on

threaded-end pins, adjusting pins and crankshaft crankpin.

– Tighten fastening bolts on control box evenly and in a cross

pattern.

Make sure the camshaft housing is not gripped.

Tightening torque:

Bolt M 6 to 10 Nm.

Bolt M 10 to 50 Nm.

Resume the installation in the removal reverse order.

1. Engine - disassemble and assemble

17

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

2

Engine block, seals

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Remove and Install ⇒ page 18

Replace crankshaft seal - pulley side ⇒ page 19

Replace crankshaft seal - engine flywheel side ⇒ page 21

WARNING

Always replace self-locking nuts and screws subject to angular

torque

2.1

Crankshaft seals

1 - 90 Nm + 90°

❑ Replace after each re‐

moval..

❑ Fit lubricated.

❑ Immobilise crankshaft

pulley with the Spanner

-3415- .

❑ The additional angle tor‐

que can be measured

with a spanner, e.g. Ha‐

zet 6690.

2 - Washer

3 - Crankshaft pulley

❑ Remove and install

Poly-V belt ⇒ page 13 .

4 - Support sleeve

5 - Crankshaft seal (pulley

side)

❑ Replace ⇒ page 19 .

6 - Engine block

7 - 60 Nm + 90°

❑ Replace after each re‐

moval.

8 - Flywheel

9 - Intermediate plate

❑ Must seat on adjusting

guide.

❑ Do not damage/twist

while removing and in‐

stalling

10 - Crankshaft seal (flywheel

side)

❑ Replace ⇒ page 21 .

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Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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2.2

Crankshaft seal (pulley side) - replace

Special tools and workshop

equipment required

♦ Puller -3203-

♦ Torque wrench - 40 to 200

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

♦ Assembly device -T10117-

2.2.1

Removal

– Remove the Poly-V belt ⇒ page 13 .

– Remove the fastening bolts from the crankshaft pulley. Immo‐

bilise crankshaft pulley with the Spanner -3415- and -3415/1- .

– Remove centre bolt and crankshaft pulley.

– Turn inner part of Puller -2085- three turns (around 5 mm) from

external part and lock with knurled bolt.

2. Engine block, seals

19

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Lubricate puller threaded head, seat it and thread it as firmly

as possible onto the seal.

– Loosen the knurled bolt and turn the inner part against the

crankshaft until the seal is extracted.

2.2.2

Installation

– Seat Sleeve -T 10117/2- on trunnion and move seal.

– Remove Sleeve -T 10117/2- .

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– Press seal with Pressure sleeve -T10117- up to control box

stop, through uniform tappings.

Resume the installation in the removal reverse order.

20

Rep. Gr.13 - Crankshaft, pistons

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

2.3

Crankshaft seal (flywheel side) - replace

Special tools and workshop

equipment required

♦ Extraction hook -2086-

♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

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

♦ Insertion device -T10122-

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Note

♦ In order to better represent the operation sequences, tthey are

carried out with the engine removed.

♦ The operation sequences with both engine and transmission

removed are identical.

2.3.1

Removal

– Remove clutch assembly and engine flywheel.

2. Engine block, seals

21

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove seal with the Extraction hook -2086 - .

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2.3.2

Installation

Note

Only remove support ring from seal right before its installation.

– Join Assembly bearing shells -T 10122/1- and -T10122/2- .

– Move the seal -A- on Assembly bearing shell -T 10122/2- up

to the stop.

– Separate both assembly bearing shells.

– Install Assembly bearing shell -T 10122/2- with seal on crank‐

shaft flange.

– Press the seal with the Pressure bearing shell -T 10122/3- to

the stop.

Resume the installation in the removal reverse order.

22

Rep. Gr.13 - Crankshaft, pistons

Crankshaft,pistons for Your Volkswagen Fox SUV Second Generation (2003-2021)

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