Volkswagen Fox (2004 year). Manual — part 9
cation: Black line on the bearing shell surface, in the union area.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Distance from the bearing shell edge to the external edge of connecting rod/connecting rod cap: 2.5 mm,
measured from one side.
❑ Check it is securely seated.
❑ Axial clearance. Wear limit: 0.37 mm.
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm. Do not rotate crankshaft while checking
radial clearance.
7 - Engine block
❑ Check cylinder diameters
⇒ page 34
❑ Piston and cylinder dimensions
⇒ page 36
.
8 - Connecting rod cap
❑ Check installation position.
9 - Oil ejector
❑ For piston cooling.
❑ Check assembly position: Install by turning the oil ejector in counterclockwise direction up to the end.
10 - 25 Nm
❑ Insert without sealant.
11 - Connecting rod screw, 30 Nm + 90°
❑ Replace after each removal.
❑ Lubricate threads and contact surface.
❑ First tighten evenly to 5 Nm.
❑ To measure radial clearance, use old bolts.
Check piston ring gap
– Push ring firmly from above down to approx. 15 mm from bot‐
tom end of cylinder.
Piston ring
Dimensions in mm
New
Wear limit
1. compression ring
0,25...0,40
1,0
2. compression ring
0,20...0,40
1,0
Oil scraper ring
0,25...0,50
1,0
Checking ring to groove clearance
Clean groove before check.
Piston ring
Dimensions in mm
New
Wear limit
1. compression ring
0,06...0,09
0,25
2. compression ring
0,05...0,08
0,25
Oil scraper ring
0,03...0,06
0,15
Fox 2004 ➤
5. Pistons and connecting rods - dismantle and assemble
33
lateral -A- and longitudinal -B- directions, as illustrated. Max.
nominal dimension deviation 0.10 mm.
Note
The cylinder diameter cannot be measured while the engine block
is secured to the assembly stand with the Engine and gearbox
support -VW 540- , for in this case inaccurate measurements are
possible.
Installation position and correspondence to respective cylinder
Piston in cylinders 1 and 2.
Larger intake valve chamber towards the flywheel -arrows-.
Piston in cylinder 3.
Larger intake valve chamber towards the pulley -arrow-.
Note
♦
The new correspondence between pistons and cylinders is in‐
dicated by color marking on the piston head.
♦
Piston for cylinders 1 and 2: marking 1/2.
♦
Piston for cylinder 3: marking 3.
Check the piston projection at TDC
Special tools and workshop equipment required
Fox 2004 ➤
34
Test sequence
– The piston projection at TDC must be measured when instal‐
ling the new pistons. Depending on the piston projections,
install the corresponding head gasket, in compliance with the
table below:
Note
Turn the engine clockwise to check the piston projections in TDC.
Piston projection
Identification
Holes/grooves
0.91 mm...1.00 mm
1
1.01 mm...10.10 mm
2
1.11 mm...10.20 mm
3
Identification of cylinder head gasket
♦ Part number = -arrow 1-.
♦ Production control code = -arrow 2- (can be disregarded).
♦ Holes = -arrow 3-.
Note
If different figures are obtained when measuring piston projection,
the highest figure should be taken when selecting the head gas‐
ket.
Fox 2004 ➤
5. Pistons and connecting rods - dismantle and assemble
35
Dimension for fin‐
ishing
∅ Piston
∅ cilinder
Basic dimension
mm
79,47
79,51
1. rework
mm
79,97
80,01
Fox 2004 ➤
36
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