Volkswagen Workshop Service and Repair Manuals

Renewing spur gear for crankshaft, engine codes CBAA, CBAB, CBAC, CBBA, CBBB   Caution Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that the crankshaft bearings or conrod bearings are damaged. To avoid any subsequent damage, the following work must be carried out following the repair: Thoroughly clean oil channels. Renew oil cooler Renew oil filter element Special tools and workshop equipment required

t  Commercially available hotplate

t  Fitting tool -10 - 203- t  Puller -T10392- t  Thrust piece -T10392/1- t  Temperature gauge -VAS 6519- or hand-held multimeter -V.A.G 1526D- in combination with temperature sensor -V.A.G 1526D/1- –  Remove sealing flange (belt pulley end) → Chapter. –  Remove sump → Chapter. –  Remove balancer shaft module → Chapter Pulling off spur gear

–  Insert thrust piece -T10392/1- in crankshaft end.

–  Insert puller -T10392- into holes of spur gear and turn clockwise -arrow-, screw in locating pins -A-.

–  Counterhold crankshaft with ring spanner -A-, pull spur gear off crankshaft journal by screwing spindle in using ring spanner -B- or ratchet. Shrink-fitting spur gear   Note t  Check temperature when heating the new drive pulley using temperature gauge -VAS 6519-, or hand-held multimeter -V.A.G 1526D- in combination with temperature sensor -V.A.G 1526D/1-. To do this, push measuring tip of temperature sensor onto drive pulley. t  At a temperature of 200 °C there are approx. 4 seconds remaining to position the drive pulley onto crankshaft. t  There is more time for positioning at a higher temperature (220 °C = approx. 6 seconds). t  Ensure absolute cleanliness on crankshaft end.   Caution The maximum temperature of 240 °C must not be exceeded as this will lead to discolouring and distortion of the drive pulley.

–  Place new spur gear onto a commercially available hot plate and heat to at least 200 °C, maximum 240 °C. The lettering points upwards.   WARNING There is a risk of burning. Wear suitable protective gloves for further procedure.

–  When the temperature is reached, take spur gear up using pliers, as shown in illustration.   Note Take care not to damage the splines on the spur gear.

–  Slide spur gear quickly by hand without canting onto crankshaft end until stop using fitting tool -10 - 203-. –  Allow the spur gear to cool down a few minutes and then install balancer shaft module → Chapter.