Removal and Replacement

Crankshaft, removing and installing

Note:
^ Secure engine to assembly stand using engine and transmission holder VW 540 when performing repair work.





1 - 65 Nm plus an additional 90 ° (1/4 turn)
^ Replace
^ When measuring radial clearance, tighten crankshaft to 65 Nm, but do not turn further

2 - Bearing cap
^ Bearing cap 1: Belt pulley side
^ Bearing cap 3 with notches for thrust washers
^ Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another

3 - 10 Nm plus an additional 90 ° (1/4 turn)
^ Replace
^ Replace sensor wheel every time bolts are loosened

4 - Needle bearing
^ For vehicles with manual transmission

5 - Sensor wheel
^ For engine speed (rpm) sensor G28
^ Only possible to install in one position - Bores are offset
^ Replace sensor wheel every time bolts are loosened

6 - Crankshaft
^ Axial play new: 0.07 to 0.23 mm. Wear limit: 0.30 mm
^ Check radial clearance with Plastigage 0.02 to 0.04 mm Wear limit: 0.15 mm
^ Do not turn crankshaft when measuring radial play

7 - Thrust washers
^ For bearing 3
^ Observe locating point

8 - Bearing shell for cylinder block
^ With lubricating groove
^ Do not interchange used bearing shells (mark)
^ Insert bearing shells for cylinder block with proper color marking

9 - Chain sprocket
^ For chain for oil pump

10 - Bearing shell for bearing cap
^ Without lubricating groove
^ Do not interchange used bearing shells (mark)
^ The crankshaft bearing shells in bearing caps are only available as a replacement part with a "yellow" color marking.





Sensor wheel, removing and installing
- Always replace sensor wheel - 2 - whenever bolts are removed - 1 -.

Note:
^ After tightening a second time, the attachment point of the countersunk screws of the sensor wheel are so deformed that the screw heads lie on the crankshaft - 3 - -arrows - and the sensor wheel is loose underneath the screws.
^ Installation of sensor wheel is only possible in one position - the bores are offset.

Torque specifications





Allocation of crankshaft bearing shells for cylinder block
The cylinder block is allocated with bearing shells of the correct thickness in the factory. Colored spots serve to identify the bearing thicknesses.

Note:
^ Arrow points in direction of travel.

The letters marked on lower sealing surface of cylinder block identify which bearing shell must be installed in which location.