Volkswagen Fox (2004 year). Manual - part 5

move and install

Note

WARNING

Always replace self-locking nuts and screws subject to angular

torque

1 - Seal

❑ Do not apply additional

lubricant or grease to

the seal lip.

❑ Before installation, re‐

move oil residues from

crankshaft trunnion with

a clean cloth.

❑ Replace crankshaft oil

seal - pulley side

⇒ page 18

2 - Sealing flange

❑ Must be positioned on

the fixing guides.

❑ Remove and install

⇒ page 20

 .

❑ Install with Silicone seal

-D176404 A2-

⇒ page 20

 .

3 - Engine block

❑ Removing and installing

crankshaft 

⇒ page 29

❑ Disassemble and as‐

semble pistons and con‐

necting rods

⇒ page 32

4 - Engine flywheel

❑ To remove and install

the flywheel, immobilise

with the Flywheel lock

-3386-

5 - 60 Nm + 90°

❑ Replace after each re‐

moval.

6 - Intermediate plate

❑ Must be positioned on fixing guides.
❑ Do not damage / bend during assembly

7 - 15 Nm
8 - Sealing flange with seal

❑ Complete replacement only.

Fox 2004 ➤

2. Crankshaft flanges and flywheel - remove and install    

17

 

Crankshaft oil seal, pulley side - replace

Special tools and workshop

equipment required
♦ Extractor -3203-
♦ Lock -3415-
♦ Assembly sleeve -T10053-
♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

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

2.1.1

Removal

– Remove Poly-V belt 

⇒ page 14

 .

– Remove timing belt 

⇒ page 41

 .

Fox 2004 ➤

18

 

– To guide the seal Extractor -3203- , install the gear fastening

screw manually up to the crankshaft stop.

– Give the inside part of the Extractor -3203- two turns (approx.

3 mm) from the external side, and lock with the slotted bolt.

– Lubricate the threaded head of the oil seal Extractor, -3203-

install and screw as firmly as possible onto the seal.

– Loosen the slotted screw and turn the inner part against the

crankshaft until the seal is extracted.

2.1.2

Installation

Note

Do not apply additional lubricant or grease to the sealing lip of the

oil seal.

– Before installation, remove oil residues from crankshaft trunn‐

ion with a clean cloth.

– Fit the Guide sleeve -T10053/1- onto the crankshaft trunnion.
– Slide oil seal over the Guide sleeve -T10053/1- and over the

end of the crankshaft.

Fox 2004 ➤

2. Crankshaft flanges and flywheel - remove and install    

19

 

Centre bolt -T10053/3- .

– Install and adjust timing belt 

⇒ page 41

 .

2.2

Crankshaft seal flange - replace

Special tools and workshop

equipment required
♦ Lock -3415-
♦ Assembly sleeve -T10053-
♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

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

♦ Hand drill plastic brush
♦ Silicone seal -D176404 A2-
♦ Flat spatula

2.2.1

Removal

– Remove Poly-V belt 

⇒ page 14

 .

– Remove timing belt 

⇒ page 41

 .

Fox 2004 ➤

20