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 BDC, BGD

Note: The balancer shaft gear assembly must be adjusted.

1. Chain sprocket
2. 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)
3. 65 Nm + 90° (1/4 turn) further
^ Replace
^ Threaded along complete length (screw)
^ Tighten to 65 Nm when measuring crankshaft radial clearance
4. Bearing cap
^ Bearing cap 1: Ribbed belt pulley end
^ Bearing cap 3 with recesses for thrust washers
^ Bearing shell retaining lugs (cylinder block/bearing cap) must be on same side
5. Bearing shell 3
^ Position 2
^ Do not interchange used bearing shells (mark)
6. Sensor wheel
^ Replace
^ For Engine speed (RPM) sensor -G28-
^ Can only be installed in one position. Holes are offset
7. 10 Nm + 1/4 turn (90°) further
^ Replace
8. Thrust washer
^ For bearing 3 bearing cap
^ Observe adjustment
^ Lettering faces mounting bracket
9. 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: 0.07 mm
^ Do not rotate crankshaft when checking radial clearance
^ Refer to Crankshaft dimensions
10. Thrust washer
^ For cylinder block, bearing 3
^ 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)