Crankshaft: Service and Repair

Crankshaft, removing and installing

Note:
^ When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 and supplementary set 540/1 B.
^ Before removing the crankshaft, ensure that a suitable place has been prepared, to ensure that the sensor wheel (item 6) does not make contact or become damaged.
^ When changing bearing shells ensure that bearing shells of same color code are used.

1. Bearing cap
^ Bearing cap 1: Vibration damper end
^ Bearing cap 5 with recesses for thrust washers
^ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
2. 30 Nm plus additional 1/2 turn (180°) further
^ Replace
^ Turning 2 x 90° further is permitted
3. Bearing shells 1...7
^ Observe note before removing, Refer to note above
^ For bearing cap without oil groove
^ For cylinder block with oil groove
^ Do not interchange used bearing shells (mark location)
4. Thrust washer
^ For bearing cap 5
^ Observe fixtures
5. Crankshaft
^ Axial clearance new: 0.07 0.24 mm, Wear limit: 0.30 mm
^ Check radial clearance with Plastigage, New: 0.02 0.06 mm, Wear limit: 0.10 mm
^ Do not turn crankshaft when checking the radial clearance
^ Crankshaft dimensions: Main bearing: 59. 958... 59. 978 mm Connecting Rod bearing: 53.958 .... 53.978 mm
6. Sensor wheel
^ For Engine speed (RPM) sensor -G28
^ Replace
^ Installing
7. 10 Nm plus additional 1/4 turn (90°) further
^ Replace
^ Observe sequence when tightening 1
8. Oil spray jet
^ For piston cooling
^ Opening pressure: 2.0 bar
^ Removing and installing, Refer to Engine Lubrications, Service and Repair, Lubrication System, Component servicing
^ See note, Refer to Note Above





Fig. 1 Installing sensor wheel to crankshaft
Special tools and equipment
^ VAG 1331 Torque wrench (5...50 Nm)
^ D 000 600 A2 Locking compound

Work sequence
Make sure crankshaft/sensor wheel contact surfaces are free of oil and grease.
- Apply a thin coat of locking compound D 000 600 A2 to contact surfaces of crankshaft and sensor wheel for additional security.
- Note when installing, "VR6" -arrow- is marked at individual threaded holes.
- Tighten all new securing bolts lightly by hand.
- Tighten securing bolt -1- to 10 Nm plus additional 90° (1/4 turn).
- Tighten securing bolts -2- to 10 Nm plus additional 90° (1/4 turn).