Removing and installing crankshaft — VW

The work sequence for removing and installing the crankshaft in the New Beetle RSi is fundamentally similar to the Golf 1998 ä, Bora 1999 ä; 6-cyl. injection engine, mechanics with engine code AUE.

The following description deals with the Golf 1998 ä, Bora 1999 ä. Therefore differences must be considered, if necessary.

Notes:

Before removing the crankshaft, ensure that a suitable surface is prepared to ensure that the sender wheel (item
6
) is not damaged or lies against any other item.
When stripping and assembling the engine it should be secured to the engine frame with engine bracket 3269.
When changing bearing shells ensure that bearing shells of same colour code are used.

Bearing cap
Bearing cap 1: Vibration damper end
Bearing cap 5 with recesses for thrust washers
Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side

30 Nm + 1/2 turn (180°) further
Renew
2 x 90°further is permitted

Bearing shells 1 ... 7
For bearing cap without oil groove
For cylinder block with oil groove
Do not interchange used bearing shells (mark)

Thrust washer
For bearing cap 5
Note fixing arrangement
From engine code AUE only in bearing cap

Crankshaft
See notes before removing => Page
13-34
Axial clearance new: 0.07...0.23 mm
Wear limit: 0.30 mm
Check radial clearance with Plastigage
New: 0.02...0.06 mm
Wear limit: 0.10 mm
Do not rotate the crankshaft when checking the radial clearance
Crankshaft dimensions:
Main journal:
59.958 ... 59.978 mm
Crankshaft journal:
53.958 ... 53.978 mm
reworking is not permitted

Sender wheel
For engine speed sender (G28)
Renew
Installing => Fig.
1

10 Nm + 1/4 turn (90 °) further
Renew

Thrust washer
For cylinder block, bearing 5
Note fixing arrangement

Oil spray jet
For crankshaft bearings 2...7
For piston cooling
Opening pressure: 2.0 bar
Removing and installing
=> Page
17-10
, Fig.
1
See note
=> Page
13-4

Fig.1
Fitting sender wheel to crankshaft

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

V.A.G 1331 Torque wrench (5...50 Nm)
D 000 600 A2 Locking fluid

Work sequence

Ensure crankshaft/sender wheel contact surfaces are free of oil and grease.

Apply a thin coat of locking fluid D 000 600 A2 to contact surfaces between crankshaft and sender wheel for additional hold.
When installing, ensure that the marking -VR6- (arrow) is over the single threaded drilling.
First hand tighten all new securing bolts.
First tighten securing bolt -1- to
10 Nm + 90° (1/4 turn).
Then tighten securing bolts -2- to
10 Nm + 90° (1/4 turn).