Remove and install crankshaft: VW (UGA, UKA)

VW
Kombi
1997
Engine
4-cylinder injection engine. (Engine 1.6 I)
Edition
09.04
Remove and install crankshaft
Note
For assembly jobs, the engine should be fastened to the assembly stand with the
Support
VW 307
.
Before performing assembly jobs, it is necessary to lubricate support and sliding surfaces.
Engine flywheel banjo bolt
Tighten with a 315 to 385 Nm torque. Apply Loctite 271 (see Chemical Materials Manual)
Washer
Engine flywheel
Remove and install
Chapter
Upper compression ring
Dislocate cuts by 120 °
Remove and install segment rings using ring pliers
The mark
“TOP”
must point towards the piston head
Check gap opening of the segment rings
Fig.
Check ring clearance in the piston narrow channel
Fig.
Lower compression ring
Dislocate cuts by 120 °
Remove and install segment rings using ring pliers
The mark
“TOP”
must point towards the piston head
Check gap opening of the segment rings
Fig.
Check ring clearance in the piston narrow channel
Fig.
Oil scraper ring
Dislocate cuts by 120 °
Remove and install segment rings using ring pliers
The mark
“TOP”
must point towards the piston head
Check gap opening of the segment rings
Fig.
Check ring clearance in the piston narrow channel
Fig.
Piston pin
Piston
Remove and install
Chapter
Check clearance between cylinder and piston
Chapter
Mark assembly position and correspondence to respective cylinder
The piston head arrow should indicate the direction to the pulley
Install with the ring compressor
Concord bearing shell 3
Crankshaft gear
Thrust washer
Distributor command gear
Retention ring of the distributor command gear
conrod bearing shell 4
Oil deflecting washer
Crankshaft pulley bolt
Tighten with a 40 to 50 Nm torque
Ribbed belt
Remove and install, adjust
Chapter
Washer
Crankshaft pulley
Remove and install
Chapter
Piston pin retaining ring
Replace
Rod
The numbers stamped on the covers and rods must be turned to the same side
The forged marks must be turned upwards.
Rectify
Chapter
Rod bushing
Replace
Chapter
Piston rod nut
Tighten with a 40 to 50 Nm torque
Woodruff key
Crankshaft
Axial clearance:
New: 0.07...0.13 mm
Wear limit: 0.15 mm
Adjust (axial clearance)
Chapter
Measure radial clearance with Plastigage:
New: 0.04...0.10 mm
Wear limit: 0.18 mm
Do not rotate crankshaft while measuring radial clearance.
Crankshaft specifications
Chapter
Disassemble and assemble
Chapter
Rod conrod bearing shell
Rod bolt
Piston rod cap
Spacer washers
To adjust crankshaft axial clearance
Flywheel seal
Replace
Chapter
Sealing ring
Flywheel guide pin