Crankshaft: Service and Repair

Crankshaft, assembly overview
^ When working on the engine, it should be secured to the holding fixture VW 540 with spacers VW 540/1 B to the assembly stand.





1 - Oil pump

2 - 15 Nm

3 - 65 Nm plus 1/4 turn (90°)
^ Replace
^ Threaded along complete length
^ Tighten to 65 Nm when measuring radial clearance

4 - Bearing cap
^ Bearing cap 1: Belt pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining lugs in cylinder block and bearing caps must align

5 - Bearing shell 3
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
^ Classification for ordering spare parts

6 - Sender wheel
^ Replace
^ For Engine speed (RPM) sensor -G28-
^ Can only be installed in one position. Holes are offset

7 - 10 Nm plus 1/4 turn (90°)
^ Replace

8 - Thrust washer
^ For bearing 3 bearing cap
^ Note fixing arrangement
^ Lettering faces mounting bracket

9 - Crankshaft
^ Axial clearance:
- New: 0.070.23 mm
- Wear limit: 0.30 mm
^ Check radial clearance with Plastigage
- New: 0.010.04 mm
- Wear limit: 0.15 mm
^ Do not rotate crankshaft when checking radial clearance

10 - Thrust washer
^ For bearing 3 bearing cap
^ Spare part version (2 part), lower thrust washers are only semicircular
^ Note fixing arrangement
^ Lettering faces mounting bracket

11 - Bearing shells 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 spare parts.

12 - Chain sprocket
^ For oil pump drive





Crankshaft bearing shell identification for cylinder block (gradual introduction)
During production a bearing shell of the correct thickness is allocated to the cylinder block. Colored marks are used to identify the thickness of the bearing shells.

Note:
^ The - arrow - shows the direction of travel.

Which thickness of shell should be installed to which location is marked by a letter on the lower sealing surface of the cylinder block.

Color code





Note:
^ If the color code is not stamped or is not legible then use the middle sized (red) bearing shell.
^ The lower crankshaft bearing shells are always supplied, as a spare part, with the color code "yellow".