Volkswagen Fox (2004 year). Manual — part 8
Note
♦
Before removing crankshaft, make sure that a proper surface
has been prepared to ensure that the speed sensor rotor is not
damaged, or does not touch another item.
♦
All bearing and running surfaces must be lubricated before
assembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
1 - Bearing shells 1, 2 and 4
❑ For bearing shells with‐
out oil groove.
❑ For engine block with oil
groove.
❑ Do not interchange
used bearing shells
(mark)
2 - 65 Nm + 90°
❑ Replace after each re‐
moval.
❑ To measure radial clear‐
ance, tighten to 65 Nm,
and no further.
3 - Bearing cap
❑ Bearing cap 1: Pulley
side.
❑ Bearing shell retaining
tabs (block/bearing cap)
4 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For engine block with oil
groove.
5 - Speed sensor rotor
❑ To Engine speed sensor
- G28-
❑ Replace if damaged.
❑ Replace sensor rotor
each time bolts are loos‐
ened
❑ Remove and install.
⇒ page 30
6 - 10 Nm + 90°
❑ Replace after each removal.
7 - Fitted pin
❑ Check the projection from crankshaft
⇒ page 30
Fox 2004 ➤
4. Crankshaft - remove and install
29
⇒ page 29
.
❑ Axial clearance new: 0.07...0.17 mm. Wear limit: 0.37 mm.
❑ Check radial clearance with Plastigage. New: 0.03...00.08 mm. Wear limit: 0.17 mm.
❑ Do not rotate crankshaft while measuring radial clearance.
❑ Crankshaft dimensions
⇒ page 30
.
9 - Stop ring
❑ To engine block, bearing 3.
Check fitted pin projection out of crankshaft
Special tools and workshop equipment required
♦ Depth gauge
Test sequence
– Use Depth gauge to check projection -a- of fitted pin, with
speed sensor wheel -1- removed.
1 - Speed sensor rotor.
2 - Securing bolt.
3 - Projection of fitted pin -3- out of crankshaft a =2.5...3.0 mm.
Removing and installing speed sensor rotor
– Replace speed sensor rotor -2- each time the bolts -1- are
loosened. Tightening torque: 10 Nm + 90°.
Note
When the bolts are tightened for the second time, the contact
point on the speed sensor rotor is sufficiently deformed to enable
the bolt head to touch -arrows- on the crankshaft -3-, thus ena‐
bling the speed sensor wheel to remain loose under the bolts.
4.1
Crankshaft dimensions
(in mm)
Dimension for fin‐
ishing
Crankshaft trunnion
-∅
Connecting rod
pin-∅
Basic dimension -0,022
54,00
-0,042
-0,022
47,80
-0,042
First rework
-0,022
53,75
-0,042
-0,022
47,55
-0,042
Fox 2004 ➤
30
Crankshaft trunnion
-∅
Connecting rod
pin-∅
Second rework
-0,022
53,50
-0,042
-0,022
47,30
-0,042
Third rework
-0,022
53,25
-0,042
-0,022
47,05
-0,042
Fox 2004 ➤
4. Crankshaft - remove and install
31
mantle and assemble
Note
All bearing and running surfaces must be lubricated before as‐
sembly.
WARNING
Always replace self-locking nuts and screws subject to angular
torque
1 - Piston ring
❑ Displace the apertures
in 120°.
❑ Remove and install us‐
ing the piston ring pliers.
❑ The mark “TOP” should
face the piston head.
❑ Check ring gap
❑ Check ring to groove
clearance
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and correspond‐
ence with respective
cylinder
⇒ page 34
❑ The arrow on the piston
head should be pointed
in the direction of the
pulley.
❑ Install by using a piston
ring compressing tool.
❑ Replace piston in case
of cracks on its skirt.
❑ Check the piston projec‐
tion at TDC
⇒ page 34
3 - Piston pin
❑ In case of difficulties in
the removal, heat the
piston to 60 °C.
❑ Remove and install with
Puller and fitter -VW 222
A- .
4 - Piston pin retaining ring
5 - Connection rod
❑ Only replace as a set.
❑ Mark correspondence with cylinder -A-.
❑ Mounting position: Marks -B- shall point towards the pulley.
Fox 2004 ➤
32
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