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BAM Crankshaft Tolerances

Discussion in 'A3/S3 Forum (8L Chassis)' started by hoffmanvp3, Sep 24, 2013.

  1. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 24, 2013]
    Just a quick one chaps.
    Does any one with ElsaWin spare a few minutes and tell my the various service limits to the BAM crank shaft?
    I believe VAG offer a over size shell for the crank casing section if they require over size machining? The yellow shell?
    And vise verso with the connecting rod section of the crank.

    Cheers much appreciated.
    #1
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  3. russwuss
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    russwuss Active Member

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    [Sep 24, 2013]
    I might be able to help you tomorrow mate.. waiting for my copy to arrive (due anytime...)

    that's if no one replies today.
    #2
  4. cooper86
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    cooper86 Member

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    [Sep 24, 2013]
    hopefully this is what your after, for a bam engine code



    [TABLE="width: 100%"]

    [TD="class: spalte-text"][TABLE="class: cc abstand-kap einzug-standard"]

    [TD="class: titel-kap"]Crankshaft dimensions[/TD]
    [/TABLE]
    [TABLE="class: cc einzug-standard abstand-standard absatz-hervor"]

    Up to approx. 05.2000
    [/TABLE]
    [/TD]
    [TD="class: spalte-pfeil"] [/TD]
    [TD="class: spalte-marg"] [/TD]
    [/TABLE]
    [TABLE="class: abstand-tabelle layoutnormal frameall"]
    [TR="class: th"]
    [TD="class: cellborderrightbottom-th"]Honing dimension
    (in mm)[/TD]
    [TD="class: cellborderrightbottom-th, colspan: 2"]Crankshaft main
    bearing journal Ø[/TD]
    [TD="class: cellborderbottom-th, colspan: 2"]Conrod
    bearing journal Ø[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]Basic dimension[/TD]
    [TD="class: cellborderbottom"]54.00[/TD]
    [TD="class: cellborderrightbottom"]–0.022
    –0.042[/TD]
    [TD="class: cellborderbottom"]47.80[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]1st undersize[/TD]
    [TD="class: cellborderbottom"]53.75[/TD]
    [TD="class: cellborderrightbottom"]–0.022
    –0.042[/TD]
    [TD="class: cellborderbottom"]47.55[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]2nd undersize[/TD]
    [TD="class: cellborderbottom"]53.50[/TD]
    [TD="class: cellborderrightbottom"]–0.022
    –0.042[/TD]
    [TD="class: cellborderbottom"]47.30[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderright"]3rd undersize[/TD]
    [TD="class: cellbordernone"]53.25[/TD]
    [TD="class: cellborderright"]–0.022
    –0.042[/TD]
    [TD="class: cellbordernone"]47.05[/TD]
    [TD="class: cellbordernone"]–0.022
    –0.042[/TD]
    [/TR]
    [/TABLE]

    [TABLE="width: 100%"]

    [TD="class: spalte-text"][TABLE="class: cc einzug-standard abstand-standard absatz-hervor"]

    From approx. 05.2000
    [/TABLE]
    [/TD]
    [TD="class: spalte-pfeil"] [/TD]
    [TD="class: spalte-marg"] [/TD]
    [/TABLE]
    [TABLE="class: abstand-tabelle layoutnormal frameall"]
    [TR="class: th"]
    [TD="class: cellborderrightbottom-th"]Honing dimension
    (in mm)[/TD]
    [TD="class: cellborderrightbottom-th, colspan: 2"]Crankshaft main
    bearing journal Ø[/TD]
    [TD="class: cellborderbottom-th, colspan: 2"]Conrod
    bearing journal Ø[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]Basic dimension[/TD]
    [TD="class: cellborderbottom"]54.00[/TD]
    [TD="class: cellborderrightbottom"]–0.017
    –0.037[/TD]
    [TD="class: cellborderbottom"]47.80[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]1st undersize[/TD]
    [TD="class: cellborderbottom"]53.75[/TD]
    [TD="class: cellborderrightbottom"]–0.017
    –0.037[/TD]
    [TD="class: cellborderbottom"]47.55[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderrightbottom"]2nd undersize[/TD]
    [TD="class: cellborderbottom"]53.50[/TD]
    [TD="class: cellborderrightbottom"]–0.017
    –0.037[/TD]
    [TD="class: cellborderbottom"]47.30[/TD]
    [TD="class: cellborderbottom"]–0.022
    –0.042[/TD]
    [/TR]
    [TR="class: td"]
    [TD="class: cellborderright"]3rd undersize[/TD]
    [TD="class: cellbordernone"]53.25[/TD]
    [TD="class: cellborderright"]–0.017
    –0.037[/TD]
    [TD="class: cellbordernone"]47.05[/TD]
    [TD="class: cellbordernone"]–0.022
    –0.042[/TD]
    [/TR]
    [/TABLE]

    [TABLE="width: 100%"]

    [TD="class: spalte-text"][/TD]
    [TD="class: spalte-pfeil"] [/TD]
    [TD="class: spalte-marg"][/TD]
    [/TABLE]
    #3
  5. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 25, 2013]
    Thats part of the info im after.
    Was there any more info that came with those Dims Cooper? how to`s e,t,c
    Cheers
    #4
  6. cooper86
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    cooper86 Member

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    [Sep 25, 2013]
    That was the only info in that section for the crank, i'll check for any more tonight tho when i get home ;-)
    #5
  7. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Sep 25, 2013]
    #6
  8. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 25, 2013]
    Thanks cooper
    Some thing to do with the colour coding of the OEM replacement bearing shells for the crank and con rods.
    Basically if my crank is needing machined due to ware then i need the info on what size to machine it down too the the appropriate dim then there is a range of OEM replacement bearing Shells to use after the machining had been completed.
    Hope that made sense lol.

    cheers
    #7
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Sep 25, 2013]
    interesting how the tolerances vary with model year?
    wonder why?
    #8
  10. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 25, 2013]
    well mines a 2003 BAM S3 so im guessing the 5.2000 on wards is me:)
    I guess i`ll just hope my cranks journals are within sped when i strip the motor.
    Its had a full service history so im guessing the shells will ware first.
    I`ll be plasti-gauging every journal just to be safe.
    Does every one just use the green one?
    Cheers
    #9
  11. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 25, 2013]
    looks like i just answered my own question:)
    Plastigauge PL-X

    For measurements of:0.018mm to 0.045mm

    #10
  12. cooper86
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    cooper86 Member

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    [Sep 25, 2013]
    I got a green set unused if your after plastigauge
    #11
  13. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 25, 2013]
    Isn't is supposed to be the white?
    The PL-X plasi gauge Cooper?
    Thought the green wasn't small enough graduations?
    #12
  14. cooper86
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    cooper86 Member

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    [Sep 26, 2013]
    Not to sure on the measurements or even if it is a green set, its been sat in my tool box for awhile, will check what set it is an the measurements tomorrow when i'm in work an let you know ;-)
    #13
  15. cooper86
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    cooper86 Member

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    [Sep 26, 2013]
    Also if you search on youtube for "1.8 20v assembly" theres a guy that has done 4 or 5 videos of him rebuilding a 20v engine, which shows everything including fitting rings, rods, big ends and honing an measureing the tolerances an ring gaps. Its quite a handy couple of videos to watch ;-)

    I'll try an find the link for you

    Edit:

    Link found
    http://m.youtube.com/results?q=1.8 ....1ac.1.23.youtube-reduced..18.0.0.J72zMu-WsCw

    Its the second one down, 6 videos in total but only 5 to do with the assembly
    Last edited: Sep 26, 2013
    #14
  16. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 26, 2013]
    Thanks for that Cooper.
    Yea i`ve been watching those videos for dinner for the last month lol.
    My brother being a machinist and me being an engineer off shore we can fabricate just about any thing:)
    I really need to get the Elsawin Cd`s
    #15
  17. cooper86
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    cooper86 Member

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    [Sep 26, 2013]
    Yea i watched them a few times aswell before i started my rebuild lol. Yea the elsawin program is a massive help, i got mine when i had my A8 but didnt really use it that much, now that i got the S3 tho i'm using it all the time lol
    #16
  18. hoffmanvp3
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    hoffmanvp3 Active Member

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    [Sep 26, 2013]
    yea i made the mistake of buying it off the net to download it and it so big(that's what she said),25GB its usually corrupt when you finished downloading it:(
    The company has re linked me to the download link and i`ll try again when im home.
    Deff gonna buy the CD of Flea bay as its on 5 quid more:)
    #17

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