Crankshaft Removing and Installing

Crankshaft removing and installing

Notes:
^ Before removing the crankshaft, make sure that a suitable surface is prepared to make sure that the sender wheel (item 8) is not damaged or lies against any other item.
^ When disassembling and assembling the engine it should be secured to the engine frame with engine and transmission bracket VW 540 and support supplement VW5401 1B.





1-Oil pump with sprocket
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centering oil pump/ cylinder head are installed
^ Removing and installing
2-15 Nm
3-Chain sprocket
^ For oil pump drive
^ Check for wear
4-Bearing shells 1,2,3,4 and 5
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
5-65 Nm + 90° (1/4 turn) further
^ Always replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring radial clearance
6-Bearing cap
^ Bearing cap 1: Pulley end
^ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
7-Bearing shell 3
^ = Item 4
^ Do not interchange used bearing shells (mark)
8-Sender wheel
^ Always replace
^ For engine speed sender (G28)
^ Can only be installed in one position. Holes are off-set
9-10 Nm + 1/4 turn (90°) further
^ Always replace
10-Thrust washer
^ For bearing 3 bearing cap
^ Note fixing arrangement
11-Crankshaft
^ Axial clearance new: 0.07 to 0.23 mm Wear limit: 0.30 mm
- Check radial clearance with Plastigage new: 0.01 to 0.04 mm Wear limit: 0.15 mm
- Do not rotate the crankshaft when checking the radial clearance
Vehicles from approx. 05.00





Fig. 1 Upper crankshaft bearing identification
Upper bearing shells of the proper thickness are allocated to the cylinder block at the factory. Color markings are used to identify the bearing shell thickness

Note: Arrow points in direction of travel.

Letters on the lower sealing surface of the cylinder block identify which bearing thickness must be inserted at which position





Color markings
- The lower crankshaft bearing shells are always supplied as a spare part with the color marking "yellow".





Crankshaft dimensions