Crankshaft: Service and Repair

Crankshaft, removing and installing





Note:
^ Before removing the crankshaft, prepare a suitable place to set it which will ensure that the sender wheel is free and does not get damaged.
^ Before starting repair work the engine should be secured with engine and transmission bracket VW 540 and supplementary set VW 540/1 B.

1- Oil pump
^ With pressure relief valve of 12 bar
^ Before installing, check that both dowel sleeves for centralizing oil pump/cylinder block are installed





2- 15 Nm
3- Chain sprocket
^ For oil pump drive
4- Bearing shells 1, 2, 3, 4 and 5
^ Do not interchange used bearing shells (mark)
5- 65 Nm plus 90° (1/4 turn)
^ Always replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring crankshaft radial clearance
6- Bearing cap
^ Bearing cap 1: Poly V-belt pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining tabs (cylinder block/bearing cap) must be on same side





7- Bearing shell 3
^ Do not interchange used bearing shells (mark)
8- Sender wheel
^ Replace
^ For Engine speed (RPM) sensor -G28-
^ Can only be installed in one position. Holes are offset
9- 10 Nm plus 90° (1/4 turn)
^ Always replace
10- Thrust washer
^ For bearing 3 bearing cap
^ Not fixing arrangement
^ Lettering faces mounting bracket





11- Crankshaft
^ Axial clearance, New: 0.07 to 0.23 mm; Wear limit: 0.30 mm
^ Check radial clearance with Plastigage(R), New: 0.01 to 0.04 mm; Wear limit: 0.15 mm
^ Do not rotate crankshaft when checking radial clearance
12- Thrust washer
^ For cylinder block, bearing 3
^ Lettering faces mounting bracket





Fig. 1 Upper crankshaft bearing identification (gradual introduction)
In the factory the upper bearing caps are determined with the correct thickness for the cylinder block. Colored marks are used to identify the thickness of the bearing shells.
Which thickness of shell should be installed to which location is marked by a letter on the lower sealing surface of the cylinder block -x-.
Arrow indicates direction of travel (forward).