Crankshaft: Service and Repair

Crankshaft, removing and installing

Note:
^ Before removing the crankshaft, ensure that a suitable place has been prepared for it. The sensor wheel (item 6) must be free and not damaged.
^ When stripping and assembling the engine it should be secured to the engine stand with engine and transmission bracket VW 540 and supplementary set VW 540/1B.
^ The balancer shaft gear assembly must be adjusted, Refer to Oil Pump, Service and Repair

1- Chain sprocket
2- Bearing shells 1, 2, 3, 4 and 5
^ Classification for ordering spare parts, Refer to Fig. 1
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark)
3- 65 Nm 90° (1/4 turn) further
^ Replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring crankshaft radial clearance
4- Bearing cap
^ Bearing cap 1: Ribbed belt pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side
5- Bearing shell 3
^ Position 2
^ Do not interchange used bearing shells (mark)
6- Sensor wheel
^ Replace
^ For Engine speed (RPM) sensor -G28
^ Can only be installed in one position. Holes are off-set
7- 10 Nm 1/4 turn (90° ) further
^ Replace
8- Thrust washer
^ For bearing 3 bearing cap
^ Observe adjustment
^ Lettering faces toward mounting bracket
9- Crankshaft
^ Axial clearance new: 0.07 0.23 mm Wear limit: 0.30 mm
^ Check radial clearance with Plastigage; New: 0.01...0.04 mm Wear limit: 0.07 mm
^ Do not rotate crankshaft when checking radial clearance
^ Crankshaft dimensions, Refer to Crankshaft, Specifications, mechanical
10- Thrust washer
^ For cylinder block, bearing 3
^ Lettering faces toward mounting bracket





Fig. 1 Upper crankshaft bearing identification (gradual introduction)
In the factory, the upper bearing caps are allocated 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.