Removal and Replacement

Crankshaft, removing and installing

Note:
^ Before removing crankshaft, provide suitable support to ensure that sensor wheel (- 6 -) is not damaged.
^ When working on engine, secure it to engine stand using engine bracket VW540.





1 - Bearing shells 1, 2, 4 and 5
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)

2 - 65 Nm + 1/4 turn (90 °) further
^ Replace
^ When measuring radial clearance of crankshaft, tighten to 65 Nm but do not turn further

3 - Bearing caps
^ Bearing cap 1: pulley end
^ Bearing shell retaining lugs of cylinder block/bearing cap must be on same side

4 - Bearing shell 3 (top)
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)

5 - Thrust washers
^ For bearing cap, bearing 3
^ Note fixing arrangement

6 - Sensor wheel
^ For Engine speed (RPM) sensor G28
^ Can only be installed in one position, holes are offset
^ Always replace sensor wheel if bolts have been removed
^ Removing and installing

7 - 10 Nm + 1/4 turn (90 °) further
^ Replace
^ Always replace sensor wheel if bolts have been removed

8 - Pilot needle bearing
^ Pulling out and driving in go to Pilot needle bearing in crankshaft, extracting and driving

9 - Crankshaft
^ Axial clearance, New: 0.07...0.23 mm; Wear limit: 0.30 mm
Check radial clearance with Plastigage (TM)
^ New: 0.02...0.04 mm
^ Wear limit: 0.15 mm
^ Do not rotate crankshaft when checking radial clearance
^ Crankshaft dimensions

10 - Bearing shell 3 (bottom)
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)

11 - Chain sprocket
^ Drive for oil pump





Removing and installing sensor wheel

Note:
^ Always replace sensor wheel - 2 - if bolts - 1 - have been removed.
^ If the securing bolts are tightened a second time, seats for the countersunk bolt heads in the sensor wheel will be distorted to such an extent that the bolt heads will come into direct contact with the crankshaft - 3 - - arrows - and the sensor wheel will only fit loosely under the bolts.
^ It is only possible to install the sensor wheel in one position, mounting holes are offset.

Tightening Torque:

Identification of top crankshaft bearing
- Top crankshaft bearing shells are graded at factory and identified on cylinder block as shown in illustration.

Bearing shell identification by color codes

Bearing Shell Identification By Color Codes:

Lower crankshaft bearing shells supplied as replacement parts are always color-coded "yellow".