Crankshaft: Service and Repair

Crankshaft, removing and installing

Note:
^ Before removing the crankshaft, prepare a suitable surface so that the sensor wheel (item 8) is not making contact with anything and is not damaged.
^ When stripping and assembling the engine it should be secured to the engine frame with engine and transmission bracket VW540 and supplementary set VW540/1B.

1. Oil pump
^ With pressure relieve valve of 12 bar
^ Before installing, check that both dowel sleeves for centering oil pump/cylinder head are installed
^ Removing and installing, Refer to Lubrication System Components, removing and installing
2. 15 Nm
3. Chain sprocket
^ For oil pump drive
^ Check for wear
4. Bearing caps 1, 2, 4 and 5
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
^ Classification for ordering replacement parts, Refer to Crankshaft, Service and Repair
5. 65 Nm +90 (1/4 turn) further
^ Replacing
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring radial clearance
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
^ Always replace
^ For engine speed (RPM) sensor -G28
^ Can only be installed in one position (holes are offset)
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: 0.07-0.23 mm
^ Wear limit: 0.30 mm
Checking radial clearance with Plastigage:
^ New: 0.01-0.04 mm
^ Wear limit: 0.15 mm
^ Do not rotate the crankshaft when checking the radial clearance
^ Crankshaft dimensions, Refer to Crankshaft, Engine, Specifications

Vehicles from approximately 05.00





Fig. 1 Upper crankshaft bearing identification
The upper crankshaft bearings are installed with the proper thickness bearing shells from the factory. Color points are used to identify the bearing shell thickness.

Note: The arrow shows drive direction.

Letters in the lower sealing surface of the cylinder block identify which bearing thickness must be installed at which position.