Crankshaft: Service and Repair

Crankshaft, removing and installing

Note:
^ Before removing the crankshaft, prepare a suitable place to set it to ensure that the sensor wheel (item -I is free and does not get damaged.
^ When stripping and assembling the engine it should be secured to the engine frame with engine and transmission bracket VW540 and supplementary set VW540/1B.

Engine codes AEG, AVH, AZG, BEV





1. Oil pump
^ With pressure relief valve of 12 bar
2. 15 Nm
3. Chain sprocket
^ For oil pump drive
4. 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)
5. 65 Nm 90° + (1/4 turn) further
^ Replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring crankshaft radial clearance
6. Bearing cap
^ Bearing cap 1: Poly V-belt pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side
7. Bearing shell 3
^ item - 4 -
^ Do not interchange used bearing shells (mark)
8. Sensor wheel
^ Replace
^ For Engine speed (RPM) sensor -G28-
^ Can only be installed in one position. Holes are offset
9. 10 Nm + 1/4 turn (90°) further
^ Replace
10. Thrust washer
^ For bearing 3 bearing cap
^ Production version (1 -part), upper thrust washers discontinued, item -1 2 -
^ Observe method of securing
^ Lettering faces mounting bracket
11. 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: 0.15 mm
^ Do not rotate crankshaft when checking radial clearance
^ Refer to Crankshaft dimensions
12. Thrust washer
^ For cylinder block, bearing 3
^ Spare part version (2-part), lower thrust washers are only semicircular
^ Lettering faces 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 -x-.
Arrow indicates direction of travel (forward).





Crankshaft bearing color markings

Note:
^ If the colored marks have not been stamped or are no longer legible, use the average bearing shell (red).
^ The lower crankshaft bearing shells are always supplied as a spare part with the color marking "yellow".





Crankshaft dimensions
(dimensions in mm)