Volkswagen Fox 2004 Workshop Manual page 37

6 - Bearing shell
❑ Check installation position.
❑ Check version: Top bearing shell (nearest to the piston) is made with wear-resistant material. Identifi‐
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
❑ Piston and cylinder dimensions
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
1. compression ring
2. compression ring
Oil scraper ring
Checking ring to groove clearance
Clean groove before check.
Piston ring
Dimensions in mm
1. compression ring
2. compression ring
Oil scraper ring
⇒ page 34
⇒ page 36 .
New Wear limit
0,25...0,40 1,0
0,20...0,40 1,0
0,25...0,50 1,0
New Wear limit
0,06...0,09 0,25
0,05...0,08 0,25
0,03...0,06 0,15
3 - Cyl. diesel engine - Edition 02.2009
5. Pistons and connecting rods - dismantle and assemble
Fox 2004 ➤
33