Crankshaft: Service and Repair

Crankshaft, removing and installing






Note:
Attach engine to VW 540 engine bracket on assembly stand when disassembling and assembling engine.

1 - Oil pump
^ Removing and installing
=> Refer to Lubrication system components, removing and installing.

2 - 15 Nm (11 ft. lbs.)

3 - Chain sprocket
^ for oil pump drive

4 - Bearing caps 1, 2, 4 & 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.) + 90° (1/4 turn) further
- 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
- Replace
^ for engine speed sensor G28
^ Can only be installed in one position, holes are off-set.

9 - 10 Nm (7 ft. lbs.)+ 1/4 turn (90°) further
- Replace

10 - Thrust washer
- For bearing 3 bearing cap Note installation arrangement

11 - Crankshaft
^ Axial clearance new 0.07 to 0.23 mm
Wear limit: 0.30 mm
^ Check radial clearance with Plastigage
New: 0.01 to 0.04 mm
Wear limit: 0.15 mm
- Do not rotate crankshaft when checking radial clearance
^ Crankshaft dimensions


Crankshaft dimensions (in mm)

Honing Main Journal Conrod Journal
Dimension Diameter Diameter

Basic Demension 53.983...53.963 47.778...47.758

1st Undersized 53.733...53.713 47.528...47.508

2nd Undersized 53.483...53.463 47.278...47.258

3rd Undersized 53.233...53.213 47.028...47.008