Volkswagen Golf / Golf Plus. Manual - part 298

 

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Volkswagen Golf / Golf Plus. Manual - part 298

 

 

shaft flange using assembly tool -

T10134-

– Tighten hexagon nut of assembly tool -T10134- to 35 Nm us‐

ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G

1332/11- .

Note

After hexagon nut is tightened to 35 Nm, a small air gap must be

present between cylinder block and sealing flange.

2.4.7

E - Checking sender wheel installation

position on crankshaft

– Screw hexagon nut -E- to end of threaded spindle.
– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Remove assembly tool -T10134- .
– Remove sealing lip support ring.

– The sender wheel is in the correct installation position on the

crankshaft if a gap -a- = 0.5 mm exists between crankshaft

flange -A- and sender wheel -B-.

– Set vernier gauge on crankshaft flange.
– Measure distance -a- between crankshaft flange and sender

wheel.

If measurement -a- is too small:
– Press sender wheel further. 

⇒ page 31

If dimension -a- is attained:
– Tighten new securing bolts for sealing flange to 15 Nm using

alternate and diagonal sequence.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

30

     Rep. Gr.13 - Crankshaft group

 

– Install sump 

⇒ page 88

 .

– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to 60

Nm +

1

/4 turn (90°).

2.4.8

F - Re-pressing sender wheel

– Secure assembly tool -T10134- to crankshaft flange using

hexagon socket head bolts -A-.

– Hand tighten both hexagon socket head bolts.
– Push assembly tool -T10134- by hand to sealing flange.

– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.

– Tighten hexagon nut of assembly tool -T10134- to 40 Nm us‐

ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G

1332/11- .

– Check installation position of sender wheel on crankshaft

again. 

⇒ page 30

If dimension -a- is too small again:
– Tighten hexagon nut for assembly tool -T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft

again. 

⇒ page 30

2.5

Removing and installing engine speed

sender -G28-

Special tools and workshop equipment required

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2. Removing and installing sealing flange and flywheel    

31

 

mm

Note

Two different bolts are installed, check which tool is to be used.

– Remove noise insulation tray ⇒  General body repairs, exteri‐

or; Rep. Gr.  50 ; Body - front; Assembly overview - noise

insulation .

– Clamp off coolant hoses at engine oil cooler using hose clip

and pull off hoses.

– Remove oil filter bracket.
– Remove securing bolt -arrow- and pull out engine speed send‐

er -G28- .

Installation is performed in the reverse order, observing the fol‐

lowing: specified torque for engine speed sender -G28- securing

bolt: 5 Nm.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

32

     Rep. Gr.13 - Crankshaft group

 

Assembly overview - crankshaft 

⇒ page 33

Crankshaft dimensions 

⇒ page 38

 .

3.1

Assembly overview - crankshaft

1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without

oil groove.

❑ For cylinder block with

oil groove.

❑ Do not interchange

used bearing shells

(mark).

2 - 65 Nm + 

1

/4 turn (90°) fur‐

ther

❑ Renew
❑ To measure radial clear‐

ance, tighten to 65 Nm

but not further.

3 - Bearing cap

❑ Bearing cap 1: pulley

end.

❑ Bearing cap 3 with re‐

cesses for thrust wash‐

ers.

❑ Bearing shell retaining

lugs in cylinder block

and bearing caps must

align.

4 - Bearing shell 3

❑ For bearing cap without

oil groove.

❑ For cylinder block with

oil groove.

5 - Thrust washer

❑ For bearing cap 3.
❑ Note fixing arrange‐

ment.

6 - Crankshaft

❑ Axial clearance new: 0.07…0.17 mm, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage new: 0.03...0.08 mm, wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions 

⇒ page 38

 .

7 - Thrust washer

❑ For cylinder block, bearing 3

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

3. Crankshaft    

33

 

 

 

 

 

 

 

 

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