Crankshaft: Service and Repair

Crankshaft, Removing and Installing

Note:
^ Do not allow crankshaft to lie on sensor wheel -8- when removed from engine block.
^ Attach engine to VW 540 engine bracket on assembly stand when disassembling and assembling engine.
^ Use replacement bearings with same code code as original parts.






1. Oil pump
^ With 12 bar (174 psi) upper pressure check valve
^ Check that both positioning sleeves are in place before installing.
^ Replace drive gears if scored
2. 15 Nm (11 ft. lbs.)
3. Chain sprocket
^ For oil pump drive
4. Bearing caps 1, 2, 4&5
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
5. 65 Nm (48 ft. lbs.) + 90° (1/4 turn)
^ Always replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm (48 ft. lbs.) when measuring radial clearance
^ 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
6. Bearing cap
^ Bearing cap 1: Pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining lugs cylinder block/bearing cap must be on the same side
7. Bearing shell 3
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
8. Sensor wheel
^ For engine speed sensor -G28
^ Can only be installed in one position, holes are off-set.
^ Always replace
^ Installing see Fig. 1
9. 10 Nm (7 ft. lbs.) + 1/4 turn (90°)
^ Installing see Fig. 1
^ Always replace
^ 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
10. Thrust washer
^ For bearing 3 bearing cap
^ Note installation arrangement
11. Crankshaft
- Axial clearance:
- New: 0.07 - 0.23 mm
- Wear limit: 0.30 mm
- Check radial clearance with Plastigage
- New: 0.01 -0.04 mm
- Wear limit: 0.15 mm
- Do not rotate crankshaft when checking radial clearance
12. Cylinder block

Fig. 1 Sensor wheel, installing on crankshaft






Mounting surfaces of sensor wheel and crankshaft must be free of grease and oil.
- Install mounting bolts by hand.
- Torque bolts to 10 Nm (7 ft. lbs.) + 1/4 turn (90°).


Crankshaft dimensions






Measurements in mm