2003-2021 Volkswagen Fox SUV Cylinders,engineblock,support,protector -> 1.3 Installation User Manual
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Cylinders,engineblock,support,protector -> 1.3 Installation for Your Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
– Remove power-drive group support, engine-arrows-.  
– Remove power-drive group support, transmission -arrows-.  
lk  
– Remove the assembly from the front. For that, move the as‐  
sembly and lift it little by little until passing it over the front  
panel.  
Note  
The assembly must be guided carefully when lifted to prevent  
damages to the body.  
For removal works, the engine must be anchored to the Rotary  
stand for engine and transmission -VAS 6095- .  
– Remove engine flange transmission.  
– Fasten the engine to the Rotary stand for engine and trans‐  
mission -VAS 6095- .  
1.2  
Additional notes and assembly works in  
vehicles with air conditioning.  
Note  
To avoid damage to the condenser and cooling gas hoses, do not  
kink, twist nor overstretch the hoses.  
To be able to remove and install the engine without opening the  
cooling gas circuit:  
– Remove cooling gas hose clamps.  
– Remove the Poly-V belt ⇒ page 13 .  
– Remove air conditioning compressor from support with cooling  
gas pipes connected: ⇒ Heating - ventilation ; Rep. Gr. 87 ;  
Air conditioning .  
1.3  
Installation  
Installation is carried out in removal reversed order, considering  
the following:  
– Check clutch bearing for wear and replace it, if necessary.  
– Slightly lubricate clutch bearing, guide roller bearing and pri‐  
mary shaft with Grease - G 000 100- .  
– Check if guides for engine coupling and transmission are  
placed on the engine block and, if necessary, install them.  
– When lowering the subframe, make sure it will not hit the drive  
shafts.  
1. Engine - remove and install  
7
FOX 2004 ➤  
3 - Cyl. injection engine - Edition 12.2009  
– Adjust engine supports with no tension.  
Note  
Tightening torque for the assembly ⇒ page 8 .  
– Install drive shaft: ⇒ Chassis; Rep. Gr. 40 ; Front suspension .  
Vehicles with air conditioning  
– Install air conditioning compressor: ⇒ Heating - ventilation ;  
Rep. Gr. 87 ; Air conditioning .  
Continued for all vehicles.  
– Electrical connections and installation: ⇒ Current flow dia‐  
grams, Electrical fault finding and Fitting locations.  
– Install Poly-V belt ⇒ page 13 .  
– Install clutch actuator hydraulic cylinder: ⇒ Automatic/me‐  
chanical transmission; Rep. Gr. 30 ; Clutch - control system .  
– Install transmission gearshift command ⇒ Automatic / me‐  
chanical transmission; Rep. Gr. 34 ; Drive, housing .  
Continued for all vehicles.  
– Fill cooling system ⇒ page 56 .  
– Install air filter set ⇒ page 91 .  
– Adapt Engine control unit -J623- to the Accelerator butterfly  
valve control unit -J338- ⇒ Vehicle diagnosis, testing and in‐  
formation system VAS 5051.  
lk  
– Perform test drive and check fault memory ⇒ page 102 .  
1.4  
Tightening torques  
Location  
Tightening tor‐  
que  
Screws and nuts  
M 6  
M 8  
M 10  
M 12  
10 Nm  
20 Nm  
45 Nm  
60 Nm  
40 Nm  
Exhaust tube to manifold  
Support for the power-drive group  
Note  
The power-drive group support fastening screws are expansion  
screws and must be mandatorily replaced.  
WARNING  
Always replace self-locking nuts and screws subject to angular  
torque  
8
Rep. Gr.10 - Cylinders, engine block, support, protector  

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