Volkswagen Fox (2004 year). Manual - part 11

Special tools and workshop

equipment required
♦ Diesel injection pump lock‐

ing pin -3359-

♦ Pin wrench -3387-
♦ Crankshaft stop -T10050-
♦ Fitter -T10015-
♦ Torque wrench - 5 to 50 Nm

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

♦ Torque wrench - 40 to 200

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

♦ Support bracket -10-222A- with   Rack -10-222 A/1-

Fox 2004 ➤

1. Cylinder head - remove and install    

41

 

Note

Adjustment work on timing belts should only be carried out on cold

engines, as the indicator on the tensioning element changes de‐

pending on the engine temperature.

– Remove the engine cover.
– Remove the hose between intercooler and intake connecting

flange.

– Fit Support bracket -10-222 A- as shown and support the en‐

gine in its installation position.

– Remove engine support -1- and engine console -2-.
– Remove Poly-V belt 

⇒ page 14

 .

Fox 2004 ➤

42

 

ing up and the arrow on the rear section of the timing belt aligns

with shoulder on the phase sensor wheel hub -arrows-.

– Immobilise hub with Mandrel -3359- . To do this, slide mandrel

through free elongated hole on left side and into hole in cylin‐

der head.

– Lock timing belt gear at crankshaft, using Crankshaft stop -

T10050- . To do this, push crankshaft stop from the face side

of the gear into the gear teeth.

Note

The marks on the crankshaft gear and the crankshaft stop must

align. At the same time, the shaft of the crankshaft stop must en‐

gage into the hole in the sealing flange.

– Mark timing belt operation direction.
– Loosen securing nut of the tensioning element.

– Loosen the fastening bolts of the camshaft gear -1-, until the

gear can be moved into the elongated holes.

– Turn Pin wrench -3387- counterclockwise (opposite direction

of arrow) until the timing belt tensioning element can be fixed

in place using Locking pin -T10115- .

– Now, turn Pin wrench -3387- clockwise in direction of -arrow-

until stop and remove timing belt first from the water pump,

and then from the remaining gears.

1.1.2

Installation

Note

Adjustment work on timing belts shall only be carried out on cold

engines, as the indicator on the tensioning element changes de‐

pending on the engine temperature.

Fox 2004 ➤

1. Cylinder head - remove and install    

43

 

– Install timing belt at crankshaft gear, tensioning element and

camshaft gear.

Note

Make sure the tensioning element is correctly seated in rear me‐

chanical distribution guard -arrow-.

– Now, turn the tensioning element, using the Pin wrench - 3387-

in the direction of -arrow- until reaching the stop, and fit timing

belt on the water pump.

– Relieve the tension from the tensioning element by turning it

with the Pin wrench -3387- in opposite direction of arrow.

– Now, carefully turn tensioning element with Pin wrench -3387-

in the direction of arrow until the indicator is in the middle of

the gap in the base plate -arrow-.

– Secure the tensioning element in this position and tighten the

fastening nut with: 20 Nm +45°.

– Tighten fastening screws of the camshaft gear to 25 Nm.
– Remove Mandrel -3359- and Crankshaft stop -T10050- .
– Turn crankshaft twice in the engine rotation direction until it is

again in the TDC of cylinder 1.

Note

♦

When doing this, the crankshaft stop end shall engage in the

sealing flange while turning the engine.

♦

When the crankshaft is turned beyond the TDC of cylinder 1

and the crankshaft stop is not engaged in the sealing flange,

turn the crankshaft 

1

/4turn in the reverse direction in order to

readjust TDC of cylinder 1. No correction is allowed while the

engine is turning, so as to ensure the correct operation of the

crankshaft stop.

– Once the Crankshaft stop -T10050- has engaged, check

whether the gear can be locked by using the Locking pin

-3359- .

If the hub cannot be locked:
– Pull the Crankshaft stop -T10050- out of the hole in the sealing

flange and turn the crankshaft until the gear can be locked with

the Locking pin -3359- .

Fox 2004 ➤

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