Crankshaft: Service and Repair

Note:
^ Before removing the crankshaft, provide for appropriate storage to be sure that no weight is placed on the sensor wheel -6- and that it is not damaged.
^ Support the engine with support VW 540 before repairing.
^ When replacing bearing shells be sure to use shells of the same color.





1. Bearing shells: 1, 2, 4 and 5
^ For bearing caps without oil groove
^ For engine block with oil groove
^ Do NOT interchange used bearing shells (mark them)
2. 65 Nm (48 ft. lbs.) + additional 1/4 turn (90°)
^ Always replace
^ Threaded along complete length of bolt
^ To measure radial clearance tighten to 65 Nm (48 ft. lbs.) but no further
3. Bearing cap
^ Bearing cap 1: Pulley end
^ Bearing caps with recesses for thrust washers
^ Bearing shell retaining lugs, engine block/bearing cap must be on the same side
4. Bearing shell 3
^ Bearing cap W/O oil groove
^ For engine block with oil groove
^ Do NOT interchange used bearing shells (mark them).
5. Thrust washer
^ For bearing cap 3
^ Note positioning
6. Sensor wheel
^ For Engine Speed (RPM) sensor -G28
^ Installation possible in one position only, hole is offset
7. 10 Nm (7 ft. lbs.) + additional 1/4 turn (90°)
^ Always replace
^ Torque angle can be measured with Hazet 6690 torque angle meter or equivalent.
8. Dowel pin
^ Checking projection from crankshaft see Fig. 1
9. Crankshaft
^ Axial clearance
New: 0.07 to 0.17 mm
Wear limit: 0.37 mm
^ Check radial clearance with Plastigage:
New: 0.03 to 0.08 mm
Wear limit: 0.17 mm
^ Do not rotate crankshaft when checking radial clearance
^ Crankshaft dimensions
10. Thrust washer
^ For engine block, bearing 3





Fig. 1 Crankshaft dowel pin projection, checking

Special tools
^ Depth gauge

- Check projection of dowel pin with drive sensor plate -1- removed.

1. Sensor plate
2. Securing bolt
3. Projection of dowel pin -3- from crankshaft
a = 2.5 to 3.0 mm





Crankshaft dimensions (mm) part 1 of 2





Crankshaft dimensions (mm) part 2 of 2