Crankshaft: Service and Repair

Crankshaft, removing and installing

Note:
^ Before removing the crankshaft, prepare a suitable surface so that the sensor wheel -8- is not making contact with anything and is not damaged.
^ Secure engine to VW 540 engine bracket on assembly stand when disassembling and assembling engine.
^ Use replacement bearings with same color code as original parts.

1. Oil pump
^ With pressure relief valve of 12 bar (174 psi)
^ Check that both positioning sleeves are in place before installing
^ Replace drive gears if scored
^ Removing and installing, Refer to Engine, Lubrication, Service and Repair
2. 15 Nm (11 ft. lbs.)
3. Chain sprocket
^ For oil pump drive
^ Check for wear
4. 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)
5. 65 Nm (48 ft. lbs.) plus additional 90° (1/4 turn)
^ Always replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm (48 ft. lbs.) when measuring radial clearance
^ 90° additional angle can be measured with torque angle meter i.e., Hazet 6690
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 off-set.
^ Installing, Refer to Fig. 1
9. 10 Nm (7 ft. lbs.) plus additional 90° (1/4 turn)
^ Installing
^ Always replace
^ 90 ° additional angle can be measured with torque angle meter i.e., Hazet 6690
10. Thrust washer
^ For bearing 3 bearing cap
^ Note installation arrangement
11. Crankshaft
Axial clearance:
^ New: 0.07...0.23 mm
^ Wear limit: 0.30 mm
Check radial clearance with Plastigage
^ New: 0.01 0.04mm
^ Wear limit: 0.15 mm
^ Do not rotate crankshaft when checking radial clearance
^ Crankshaft dimensions, Refer to Crankshaft Engine,Specifications
12. Cylinder block
^ Pistons and connecting rods, disassembling and assembling, Refer to Piston, Service and Repair





Fig. 1 Sensor wheel, installing on crankshaft
Mounting surfaces of sensor wheel and crankshaft must be free of grease and oil.
- Install mounting bolts by hand
- Torque to 10 Nm (7 ft. lbs.) plus additional 90° (1/4 turn )