Overview - Crankshaft

• For assembly work, secure the engine on the engine and transmission holder. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER .

1. Plug
   • When replacing the cylinder block make sure that the plug is positioned.
   • Installing and insulation depth. Refer to Fig 3.
2. Cylinder Block
3. Bracket
   • For the vacuum reservoir
4. Plug
   • For the "TDC" -hole
   • There are different versions. Refer to Fig 2 for allocation and tightening specifications.
5. O-Ring
   • Replace after removing
   • For plug version "A". Refer to Fig 2
6. Bolt
   • Tightening Specifications and Sequence. Refer to Fig 5.
   • Replace after removing
7. Bearing Shell
   • Replace any worn bearing shells
   • For cylinder block with oil groove
   • Insert new bearing shells for bearing cap with proper color marking. Refer to MAIN BEARING SHELLS ALLOCATION .
   • Lubricate with engine oil
8. Alignment Sleeve
9. Crankshaft
   • Axial play, measuring. Refer to CRANKSHAFT, MEASURING AXIAL CLEARANCE .
   • Radial play, measuring. Refer to CRANKSHAFT, MEASURING RADIAL CLEARANCE .
   • Crankshaft dimensions. Refer to CRANKSHAFT DIMENSIONS .
   • Removing and Installing. Refer to CRANKSHAFT, REMOVING AND INSTALLING .
   • When installing a new crankshaft, replace the alignment sleeve -item  : Alignment Sleeve and alignment pin -item  : Alignment Pin.
   • Pay attention to the installation position of the balance shaft
10. Bearing Shell
    • For bearing cap without oil groove
    • Replace any worn bearing shells
    • Insert new bearing shells for bearing cap with proper color marking. Refer to MAIN BEARING SHELLS ALLOCATION .
    • Lubricate with engine oil
11. Alignment Sleeve
    • Quantity 2 per bearing cap
12. Bearing Cap
    • Allocation. Refer to Fig 4.
    • Retaining tabs for cylinder block/bearing cap bearing shells must lie above one another
13. Bolt
    • Replace after removing
    • Use the old bolts for radial clearance measurement
    • Tightening Specifications and Sequence. Refer to Fig 5.
14. Thrust Washers
    • Only on the crankshaft bearing "3"
    • Installation position: the oil grooves face outward
    • Note the installation position in the guide frame
15. Alignment Pin
16. Thrust Washers
    • Only on the crankshaft bearing "3"
    • Installation position: the oil grooves face outward
17. Bolt
    • Replace after removing
    • Tightening Specifications and Sequence. Refer to Fig 5.

Plug for TDC Hole Allocation and Tightening Specifications 

-- Clean the threaded hole in the cylinder block.

Plug Version "A" : 

-- Replace the O-ring after removal.

-- Clean the plug and tighten with a new O-ring to 25 Nm.

Plug Version "B" : 

-- Replace the plug after removal.

-- Tighten the plug to 40 Nm.

Plugs in the Cylinder Block - Installation and Installation Depth

Special tools and workshop equipment required 

• Pop Rivet Pliers: VAG1753B 
• Washers M4 quantity 3, commercially available

Washers, Preparing 

-- Prepare a washer with an outer diameter of approximately 7.7 mm.

Installing 

-- Insert the plugs -2- and washers -1- using the Pop Rivet Pliers: VAG1753A  , at the same time the correct installation depth is determined using the washers.

• Dimension -a- = 2.4 mm

-- Remove the washers.

Bearing Cap Allocation 

-- Allocate the bearing cap -1 to 4- as shown.

Bearing Cap - Tightening Specifications and Sequence 

• Replace bolts that were tightened with an additional turn after removing them.

-- Tighten the bolts in the steps in the sequence shown:

Step	Bolts	Tightening Specification/Additional Turn
1.	-1 to 8-	Install all the way by hand
2.	-1 to 8-	30 Nm
3.	-1 to 8-	50 Nm
4.	-1 to 8-	90° additional turn
5.	-arrows-	20 Nm
6.	-arrows-	90° additional turn