Genuine Volkswagen Passat Crankshaft

Volkswagen Passat Crankshaft Parts and Q&A

• Crankshaft
  03G-105-021-A
  Q: How can the crankshaft be removed after it has been taken out on Volkswagen Passat?

  A:

  Crankshaft could be removed only when the engine is out of the car, and supposing that the flywheel/driveplate, timing belt, oil pan, oil pump, front and rear oil seal housings, and the piston/connecting rod assemblies have been disassembled. Check the endplay before removal by clamping a dial indicator to its snout, the stem should be aligned with the crankshaft. Take the crankshaft to the back and make the dial indicator zero, followed by prying on the crankshaft to the front and re-checking the dial; the distance moved will show the endplay. In case it is greater than specification, inspect crankshaft thrust surfaces on wear and in case there is no wear, new main bearings could correct the problem. In case of the absence of a dial indicator, feeler gauges could be employed by thrusting the crankshaft forward and inserting the gauges in the crankshaft-thrust main bearing interface to detect clearance. Thrust bearing is found at the number three main bearing cap in the four cylinder engine and four on the V6 engine. Check the main bearing caps, which should have markings showing their positions, numbered in the front to the rear, or mark them accordingly. Unscrew the main bearing cap bolts slowly in order to be able to remove them with a hand, keeping track of any stud bolts so that they can be re-attached properly. Tap the caps with a soft-face hammer to keep them off of the engine block, and use bolts as levers, whenever needed, and be careful never to drop the bearing inserts. The crankshaft is to be carefully lifted out of the engine with or without help since it is heavy and care should be taken not to scuff the reluctor ring where the crankshaft position sensor is mounted. Install bearing inserts and replace the caps at their locations on the engine block and tighten the bolts to finger tight.
• Crankshaft
  06A-105-021-BM
  Q: How to install a crankshaft during engine reassembly on Volkswagen Passat?

  A:

  The first step in reassembling the engine involves crankshaft installation which assumes that engine block and crankshaft are cleaned, checked and repaired. Install the engine with bottom up and then take out the main bearing cap bolts and put the caps onto the table in the sequence of installation. In the event of being present, take off original bearing inserts out of the block and the caps with care that the bearing surfaces are clean. Wipe the rear of the new main bearing inserts and insert one in each main bearing saddle in block with the grooved one properly in place and with the oil holes in position. fit the crankshaft thrust washers according to the type of engine to be used, and clean the faces of the bearing and examine the oil holes at crankshaft. When it is known to be clean, install the crankshaft in place in the main bearings and verify the main bearing oil clearance with Plastigage, applying it on each main bearing journal of the crankshaft. Clean the bearing faces in the caps and replace them in their original positions with the arrows facing the front of the engine and screw up the bolts to the first step without any disturbance of the Plastigage. The main bearing caps should be carefully removed and then the crushed Plastigage should be compared with the scale to measure the crushed Plastigage to ensure that it is within specifications. In case of the incorrect clearance, look at dirt or oil interference, and then look at other bearing inserts. Cleanse the bearing faces of the block, and rub a thin coat of grease or assembly lube on the journals and bearing faces, taking off all traces of Plastigage. Install the crankshaft again, clean the faces of the bearings in the caps then lubricate them and fix the caps with the arrows facing forward. Trap the ends of the crankshaft till the thrust surfaces are aligned and all main bearing cap bolts re-tightened to final torque, beginning at the center and loosening to the outer. Test the crankshaft by hand rotation to test for binding and lastly test the crankshaft endplay with feeler gauges or dial indicator that it is correct provided thrust faces are undamaged and new bearings are being fitted. Install the intermediate shaft at this stage in case it is a four-cylinder engine.