Dismantling and assembling crankshaft: VW (ACD, AS)

ACD
For exchange engines observe fitting instructions => Page
13-45
.

Oil deflection plate
Hollow side shows to the pulley

Crankshaft bearing 4
oil
Groove shows to the oil deflection plate

Retaining ring
Removing => fig.
1
.
Installing => fig.
2
.

Distributor - input gear
Remove together with crankshaft pulley => fig.
3
Install like crankshaft => page
4
, heat at 80 °C first

Intermediate ring
Crankshaft pulley
Pressing off => fig.
3
.
Install like crankshaft => page
4
, heat at 80 °C first

Crankshaft bearing 3
oil
Dowel pin shows to the crankshaft side

Bearing shell
observe installation position, do not interchange

Crankshaft
Clean
Blow oil channels with compressed air
Do not store without protection against corrosion

35 Nm (3.5 mkg)
Oil contact surface

Conrod bush
Removing and installing => fig.
10
.
Ream => fig.
14

Conrod
Installing => fig.
6
,
7
and
8
Reworking => fig.
5
Checking axial clearance => Fig.
9
Repairing => fig.
10
to
14
Weigth difference max. 10 g

Fig.1
Removing circlip

Fig.2
Installing circlip

Fig.3
Remove crankshaft pulley together with distributor input gear

Fig.4
Install crankshaft pulley and distributor input gear

Fig.5
Reworking conrod

Note:

Install only new conrods in an engine whose weight difference is not more than 10 g.

If one or more conrods must be renewed, all four must be weight as only two weight classes are supplied.

Conrods with overweight must be reworked at the points indicated in the figure, if necessary. By doing this a weight reduction of approx. 8 g can be reached.

Fig.6
Conrod - installation position

The chained marking at the conrod shaft must lie upwards when installing.

Fig.7
Conrod - installation position

The figures on the joint between the conrod upper and lower parts must be on one side.

Fig.8
Installing conrod

Slight stress which may occur when tightening the conrods between the mounting halves can be rectified by tapping lightly on both conrod sides with a hammer.

Fig. 9
Checking conrod axial clearance

max. 0.7 mm

Servicing conrods

Conrods which are slightly bent or whose bushes are worn, must be straightened out and the bush renewed.

Fig.10
Press rod bush in and out

Fig.11
Tension conrod in the device

A -
Mounting drift 214 f 6
B -
Locking lever
C -
C-washer
D -
Support
E -
Pin
F -
Gauge

Fig.12
Align conrod

Turn the drift so that the milled side is at right-angles to the conrod centre axis.
After sliding on the C-washer tighten locking lever only so far that the conrod can still be moved in both directions. The support is loosened.
Introduce the pin into the conrod eye and push with two fingers onto the drift so that no tilt is caused between the drift and the conrod bearing or between the conrod eye and the pin.

Fig.13
Checking conrod

Check conrod for torsion and parallelism with gauge (the figure shows checking and parallelism).

When having deviations tighten locking lever tightly and align conrod with a drift.

Press conrod bush in.
Drill oil holes (3.5 mm ø).

Fig.14
Ream conrod bush

Pass reamer rod through the conrod eye and the respective device hole. The conical bush centres the conrod bush.

Tighten locking lever and conrod support, take centre bush off and ream conrod bush.
The inner bush surface must be free of grooves or scratches after reaming. The piston pin must be able to be inserted without oil, with light finger pressure.

Note:

If a bush is reamed to much it must be renewed. It is not permitted to install a piston pin of bigger diameter.

Check torsion and parallelism again with inserted piston pin in the way described before. Slight difference still existing can be compensated by aligning after having introduced a drift in the piston pin.