Get Crankshaft,pistons -> 1 Engine - disassemble and assemble 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

10

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- .

12

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

Crankshaft,pistons -> 1 Engine - disassemble and assemble for Your Volkswagen Fox SUV Second Generation (2003-2021)

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