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