Get Cylinderhead,valvecontrolmechanism -> 1 Cylinder head Guide for Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

15 – Cylinder head, valve control mechanism

1

Cylinder head

Note

♦ When assembling a new cylinder head, it is necessary to lu‐

bricate with oil all stop surfaces between supporting elements,

roller rockers and camshaft eccentrics, before installing cylin‐

der head cover.

♦ Plastic holders supplied for protecting open valves can only

be removed immediately before installing the cylinder head.

♦ When you replace engine cylinder head, it is necessary to re‐

place cooling system liquid.

♦ Remove and install intake manifold and injection valves

⇒ page 89 .

Cylinder head - remove and install ⇒ page 25 .

Distribution times - check ⇒ page 28 .

Roller chains - remove and install ⇒ page 30 .

Distribution times - adjust ⇒ page 32 .

Compression - check ⇒ page 35 .

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1. Cylinder head

23

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.1

Cylinder head - disassemble and assemble

1 - Cylinder head cover

❑ Sealing surface cannot

be ground.

❑ With integrated cam‐

shaft bearings.

❑ Remove residues from

old gasket.

❑ 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 - Sealing

❑ Replace if damaged.

3 - Oil filler cap

4 - 20 Nm

5 - Lifting eye

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6 - Engine cylinder head screw

❑ Replace.

❑ Observe installation in‐

structions and se‐

quence for loosening

and tightening

⇒ page 25 .

7 - From air filter set

8 - Vacuum tube

9 - Hall Sensor -G40-

10 - 10 Nm

11 - Sealing ring

❑ Replace if damaged.

12 - 10 Nm

13 - Support

❑ For harnesses.

14 - Oil pressure switch - F1- 0.3...0.6 bar, 25 Nm

❑ Check ⇒ page 50 .

15 - Sealing

16 - Cylinder head sealing gasket

❑ Metallic gasket.

❑ Replace.

❑ After replacement, replace the cooling system fluid.

17 - Guide bolts

❑ Tightening torque: 20 Nm

18 - Lifting eye

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Rep. Gr.15 - Cylinder head, valve control mechanism

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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1.2

Cylinder head - remove and install

Special tools and workshop

equipment required

♦ Guides -3450-

♦ Support -T10358-

♦ Torque wrench - 5 to 50 Nm

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

♦ "Torque wrench - 40 to 200

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

1332-

♦ Support or VW 061

-10-222A-

•

The engine must be warm, at most.

1.2.1

Removal

– Dismount the engine cover by pulling on the places marked

with -arrows-.

– Install Support or VW 061 -10-222A- , as illustrated, and install

on lifting eye-arrow-.

– Remove control box ⇒ page 15 .

– Remove water pump pulley.

1. Cylinder head

25

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Pull out the intake air duct of the air filter-arrow-.

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Engage the first gear so that the fastening element of the gear

selection cable -1- allows access to the transmission fastening

nut -2- and battery earth strap.

– Loosen the transmission fastening nut and battery earth strap

and install the Support -T10358- , as illustrated.

– Engage the hooks on the Support or VW 061 -10-222A - to the

Support -T10358- , as illustrated.

– Turn the spindle until the hooks are subjecto to a slight tension.

– Disengage hook -1-from the left lifting eyelet and move the left

spindle on the Support or VW 061 -10-222A- .

– Remove intake manifold ⇒ page 89 .

– Remove the roller chains ⇒ page 30 .

– Remove the engine cylinder head cover.

– Remove entire fuel distributor, with all injection valves, from

the engine cylinder head.

– Disconnect all the other connection tubes of the cooling, vac‐

uum and intake systems from the engine cylinder head.

– Loosen front exhaust pipe from exhaust manifold.

26

Rep. Gr.15 - Cylinder head, valve control mechanism

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Loosen and remove screws from the engine cylinder head ac‐

cording to the sequence indicated.

– Remove engine cylinder head carefully.

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1.2.2

Installation

Note

♦ Only remove the new cylinder head sealing gasket from the

package immediately before installation.

♦ Handle the new gasket as carefully as possible. Damages

cause leaks.

– Place clean cloths on the cylinders so as to prevent polishing

impurities and residues from entering the cylinders and pis‐

tons.

– Prevent polishing impurities and residues from entering cool‐

ing system.

– Carefully clean engine cylinder head and engine block sealing

surfaces. Make sure no sores or burrs are produced (when

using sandpaper, the grain shall not be lower than 100).

– Carefully remove polishing and sand paper residues as well

as the cloths.

– Place cylinder 1 piston in TDC and quickly return crankshaft.

– Install new cylinder head gasket on centering guides-A-. In‐

scription (part number) -B- must be visible.

– Install engine cylinder head, install the 8 bolts manually.

1. Cylinder head

27

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Tighten engine cylinder head bolts in the indicated tightening

sequence.

– Tighten screws to 30 Nm.

– Then, tighten the bolts at 90° with a hard spanner.

– Then, tighten 90° further.

Note

When turning the camshaft, the crankshaft cannot be in TDC.

Risk of damages to the valves/pistons.

– Adjust distribution times ⇒ page 28 .

– The remaining assembly steps are made by inverting the dis‐

assembly sequence, paying attention to the following:

– Fill cooling system ⇒ page 56 .

Check engine cylinder head for bending.

Max. permissible bending: 0.05 mm

1.3

Distribution times - check

Special tools and workshop equipment required

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♦ Fastening pins -T10120-

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Rep. Gr.15 - Cylinder head, valve control mechanism

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ Fastening pins -T10121-

Test sequence

– Remove Hall Sensor -G40- -arrow-.

– Remove Engine speed sensor -G28- -arrow-.

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– Turn crankshaft by the pulley fastening bolt in the engine

speed direction, until the camshaft groove is visible in the hole

designated to the Hall Sensor -G40- .

1. Cylinder head

29

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– The Pin -T10120- should fit into the camshaft easily.

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– Lock crankshaft by fitting the Pin -T10121- into flywheel hole.

Note

If the Pin -T10121- does not fit easily, remove the Pin -T10120-

from camshaft. Turn crankshaft in the engine speed direction

(360°) and repeat the operation.

If it is not possible to insert both fastening pins:

– Synchronize distribution times ⇒ page 32 .

If it is possible to insert both fastening pins:

– Remove both fastening pins from the holes and install both

sensors again.

Resume the installation in the removal reverse order.

1.4

Roller chains - remove and install

Special tools and workshop equipment required

♦ Wrench -T10172-

♦ Special wrench -3036-

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Rep. Gr.15 - Cylinder head, valve control mechanism

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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.4.1

Removal

– Remove control box ⇒ page 15 .

– Fasten camshaft and crankshaft ⇒ page 28 .

– Remove torsion spring -1- with a screwdriver from threaded-

end bolt.

– Remove fastening bolt -2- and remove chain stretcher.

– Loosen fastening bolt -3-. To immobilise the gear, use the

Spanner -T10172- .

– Remove oil pump gear, roller chain and primary gear as a set.

– Press tensioning chute manually in the -arrow direction- and

lock chain stretcher with the Pin -T40011-

– Loosen fastening screw. To do so, use the Special spanner

-3036- .

– Remove tensioning chute and sliding chute from guide pins by

pulling them forwards.

– Remove roller chains from the gears.

1.4.2

Installation

– Run roller chain on crankshaft gear and camshaft gear.

– Push tensioning chute and sliding chute forwards on the guide

pins.

– Install camshaft gear with a new fastening bolt.

Tighten fastening bolts to 20 Nm + 90°.

– To do so, use the Special spanner -3036- .

– Put the oil pump roller chain together with the two chain gears.

– Screw oil pump gear with the new fastening bolt.

1. Cylinder head

31

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

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Tighten fastening bolts-3- to 20 Nm + 90°

– Assemble oil pump activation chain stretcher.

Tightening torque -2- for the chain stretcher fastening bolt: 15 Nm

– To do so, use the Spanner -T10172- .

– Install the torsion spring -1- with a screwdriver on the threa‐

ded-end bolt.

– Adjust distribution times ⇒ page 32 .

– Install control box ⇒ page 15 .

1.5

Distribution times - adjust

Special tools and workshop

equipment required

♦ Torque wrench - 40 to 200

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

♦ Torque wrench - 5 to 50 Nm

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

♦ Standart-type clamp pliers -

VW 5162- or Standart-type

clamp pliers -VAS 5024A-

♦ Special wrench -3036-

♦ Wrench -3415-

♦ Pins -3415/1-

32

Rep. Gr.15 - Cylinder head, valve control mechanism

Cylinderhead,valvecontrolmechanism -> 1 Cylinder head for Your Volkswagen Fox SUV Second Generation (2003-2021)

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