Crankshaft - remove and install — VW

VW
Golf
1999
Engine
4 - Cyl. injection engine
Edition
08.2010
Crankshaft - remove and install
Note
Before removing the crankshaft, provide a proper platform in order to place it, without leaning, on the
Engine speed sensor
G28
rotor in order not to damage it.
To proceed with the assembling works, the engine shall be fastened to the assembly stand, with the
Support for VW643 or VW 643/1
VW 313
or
Rotary stand for engine and transmission
VAS 6095
.
All contact and bearing surfaces must be lubricated with oil before assembly works.
WARNING
Always replace self-locking nuts and screws subject to angular torque.
Oil pump
Remove and install:
Chapter
.
With 12-bar overpressure valve.
Check, before installation, whether the two guides for coupling the oil pump/engine block are present.
15 Nm
Gear
For oil pump activation.
Check for wear.
Bearing shells 1, 2, 3, 4 and 5
Approx. 05.00 ▸ classification to place orders in the parts service:
Fig.
For bearing caps without lubrication groove.
For engine block, with lubrication groove.
Do not mix bearing shells to be reused (mark).
65 Nm +90°
Replace after each removal .
Continuous thread.
In order to measure the radial gap of the crankshaft, tighten firmly to 65 Nm without angular torque.
Bearing caps
Bearing cap 1: pulley side.
Bearing cap 3 with channels for adjustment rings (axial clearance).
The bearing shell fastening shoulders and the engine block/bearing cap must be overlapped.
Bearing shell 3
Approx. 05.00 ▸ classification to place orders in the parts service:
Fig.
For bearing caps without lubrication groove.
For engine block, with lubrication groove.
Do not mix bearing shells to be reused (mark).
Engine speed sensor
G28
rotor
Replace.
To the
Engine speed sensor
G28
.
installation possible only in one position (displaced holes).
10 Nm +90°
Replace after each removal.
Axial clearance adjusting ring
For the bearing 3 cap.
Pay attention on the fastening.
Crankshaft
Axial clearance: new 0.07... 0.23 mm. Wear limit: 0,30 mm.
Measure the radial clearance using the new
“Plastigage”
: 0.01...0.04 mm. Wear limit: 0,15 mm.
Do not rotate the crankshaft when measuring radial gap.
Crankshaft dimensions:
Chapter
.
Identification of crankshaft bearing shells for the engine block
Vehicles approx. 05.00 ▸
The matching between the correct thickness of the upper bearing shells and the engine block is made at factory. The bearing shell thickness is marked by color spots.
Note
The
arrow
indicates the crankshaft pulley position.
Color identification
Letter on the engine block
Bearing shell color
S
=
black
R
=
red
G
=
yellow
The crankshaft bearing shells on the bearing caps are supplied as replacement parts only with the
“yellow”
color.
Crankshaft dimensions
(Dimensions in mm)
Grinding
dimension
Crankshaft bearing
Trunnion ∅
Connecting rod bearing
Crankpin-∅
Vehicles
approx. ▸ 04.00
Vehicles
approx. 05.00 ▸
Base measure
-0,022
54,00
-0,042
-0,017
54,00
-0,037
-0,022
47,80
- 0,042
Phase I
-0,022
53,75
-0,042
-0,017
53,75
-0,037
- 0,022
47,55
-0,042
Phase II
-0,022
53,50
-0,042
-0,017
53,50
-0,037
- 0,022
47,30
-0,042
Phase III
-0,022
53,25
-0,042
-0,017
53,25
-0,037
-0,022
47,05
-0,042