Get Cylinders,engineblock,support,protector -> 1 Engine - remove and install Guide for Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

10 – Cylinders, engine block, support, protector

1

Engine - remove and install

Removal ⇒ page 4 .

Additional notes and mounting works in vehicles with air condi‐

tioning ⇒ page 7 .

Installing ⇒ page 7 .

Tightening torque ⇒ page 8 .

Special tools and workshop

equipment required

♦ Hanger or 2024A -VW 055-

♦ Hydraulic moving hoist -

500Kg or VAS 6100 -EQ

7025-

♦ Rotary stand for engine and

transmission -VAS 6095-

♦ Torque wrench - 5 to 50 Nm

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

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1. Engine - remove and install

3

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

♦ Torque wrench - 40 to 200

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

♦ Container -VAS 6208-

♦ VW 5162 or Standart-type

clamp pliers -VAS 5024A-

♦ Grease -G 000 100-

♦ Clamp

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1.1

Removal - indications

Note

Disconnect the Battery -A- earth strap for carrying out the oper‐

ation sequence below. Check if the vehicle has code radio. If

positive, request the anti-theft code before disconnecting earth

strap from the Battery -A- .

– The engine is removed from the front along with the transmis‐

sion.

– With the ignition switched off, disconnect the Battery -A- earth

strap.

– All clamps loosened or cut during engine removal must be

placed in the same position again during engine installation.

– Remove air filter set ⇒ page 91 .

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Rep. Gr.10 - Cylinders, engine block, support, protector

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove the Battery -A- and the Battery support -A- -arrows-

⇒ Electrical equipment; Rep. Gr. 27 ; Starter, generator,

battery .

– Open and close the coolant reservoir lid to depressurize the

cooling system.

– Release/separate all transmission electric cables of the Gen‐

erator (Alternator) -C- and Starter -B- .

– Loosen/separate all of the remaining necessary engine elec‐

tric cables.

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WARNING

Fuel supply tube is under pressure! Wear protective goggles

and gloves to prevent injuries and avoid contact with the skin.

Before loosening tube junctions, place a cloth around them.

Eliminate pressure, pulling the tube carefully.

– Loosen the fuel supply pipes -1- (press the unlock key).

– Remove the Electromagnetic valve for activated charcoal filter

-N80- hose on the intake manifold.

– Close the hoses so as to prevent impurities from entering the

fuel system.

– Follow cleaning rules ⇒ page 65 .

– Remove vacuum and vent hoses from the engine.

– Disengage the connectors from the Radiator fan thermal

switch -F18- and from the Radiator fan -V7- .

– Remove fastening screw from front exhaust tube support strap

in the transmission.

– Loosen front exhaust tube from catalytic converter

⇒ page 106 .

1. Engine - remove and install

5

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove transmission pendulum support -arrows-.

– Remove clutch actuator hydraulic cylinder: ⇒ Automatic / me‐

chanical transmission ; Rep. Gr. 30 ; Clutch - command

system .

– Remove transmission gearshift command: ⇒ Automatic/me‐

chanical transmission; Rep. Gr. 34 ; Drive, housing .

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– Drain the cooling system ⇒ page 56 .

– Remove engine cooling system hoses with VW 5162 or Stand‐

ard type clamp pliers - VAS 5024A- .

– Remove the Poly-V belt ⇒ page 13 .

– Put front panel in the work position: ⇒ Body - Repair ; Rep.

Gr. 50 ; Body - Front part .

Vehicles with air conditioning

– Remove air conditioning compressor: ⇒ Aeration system;

Rep. Gr. 87 ; Air conditioning and anchor to the body with a

wire.

– Observe additional indications and assembly works

⇒ page 7

Continued for all vehicles.

– Remove drive shafts, on the left and right side of the trans‐

mission, and fasten them on top: ⇒ Chassis; Rep. Gr. 40 ;

Front suspension .

– Install the Hanger or VW 055 -2024A- and lift it with a hydraulic

hoister.

Pulley side: position 1 of the vertical rod. Orifice on the sustaining

bar in position 1.

Steering wheel side: position 2 of the vertical rod. Orifice on the

sustaining bar in position 5.

Caution

Use safety pins on fitting hooks and pins so as to prevent dam‐

ages to the engine and vehicle.

Note

♦ Positions numbered 1...8 on suspension bar face the pulley

side.

♦ The holes in the supports are counted from the hook.

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Rep. Gr.10 - Cylinders, engine block, support, protector

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Remove power-drive group support, engine-arrows-.

– Remove power-drive group support, transmission -arrows-.

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– 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.

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– 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

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Rep. Gr.10 - Cylinders, engine block, support, protector

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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Power-drive group support, engine

A = 20 Nm + 90°

B = 30 Nm +90°

Power-drive group support, transmission

A = 40 Nm + 90°

B = 50 Nm +90°

C = 50 Nm +90°

Pendular support

A = 30 Nm + 90°

B = 40 Nm +90°

1. Engine - remove and install

9

Cylinders,engineblock,support,protector -> 1 Engine - remove and install for Your Volkswagen Fox SUV Second Generation (2003-2021)

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