Removal and Replacement

Assembly overview
^ Secure engine to assembly stand using holding fixture VW 540 with adapter set for engine and transmission support VW 540/1 B when performing repair work.





1 - Oil pump

2 - 15 Nm

3 - Chain sprocket
^ For oil pump drive

4 - Bearing shells 1, 2, 3, 4 and 5
^ Classification for replacement part ordering
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearings (mark)

5 - 65 Nm plus 90° (1/4 turn) additional turn
^ Replace
^ Fully threaded
^ When measuring crankshaft radial play, fasten to 65 Nm

6 - Bearing cap
^ Bearing cap 1: Belt pulley side
^ Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another

7 - Bearing shell 3
^ Do not interchange used bearings (mark)

8 - Needle bearing
^ Only vehicles with manual transmission

9 - Sensor wheel
^ Always replace
^ For Engine Speed (RPM) Sensor G28
^ Only possible to install in one position - Holes are offset

10 - 10 Nm plus 1/4 turn (90°)
^ Replace

11 - Thrust washer
^ For bearing cap, bearing 3
^ Observe locating point

12 - Crankshaft
^ Axial play new: 0.07 to 0.23 mm
- Wear limit: 0.30 mm
^ Measure radial play with Plastigage
- New: 0.02 to 0.04 mm Wear limit: 0.15 mm
^ Do not turn crankshaft when measuring radial play
^ Different versions of manual and automatic transmissions; Check part number

13 - Thrust washer
^ For bearing support, bearing 3
^ Observe locating point
^ Version for replacement part (2 part); lower thrust washers are only semicircular





Identification on crankshaft bearing, top
From the factory, the upper bearing shells are allocated to the cylinder block with the correct thickness. Color-coded dots serve to identify the bearing thicknesses.

Note: Arrow points in direction of travel.

The letters marked on the lower sealing surface of the cylinder block identify which bearing thickness must be installed in which location.

Color identification





The lower crankshaft bearing shells are always shipped as replacement part with "yellow" color marking.