Balance Shaft Spur Gear

WARNING: This page is about a different car, the 2010 Volkswagen Jetta and 2009 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Oil Seal Driver 10-203
Commercially Available Hot Plate
Puller T10392 with
Pressure Piece T10392/1
Digital Thermometer VAS 6519
Protective Gloves

Removing

-- Remove the belt pulley side sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .

-- Remove the balance shaft module. Refer to BALANCE SHAFT MODULE .

-- Insert the thrust piece T10392/1 in the crankshaft.

Fig 1: Identifying Thrust Piece T10392/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the puller T10392 in the spur gear holes and rotate it clockwise -arrow-. Install the locking pin -A-.

Fig 2: Identifying Puller T10392

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Counter-hold the crankshaft with an open end wrench -A-. Remove the spur gear by installing the spindle with the open end wrench -B- or ratchet.

Fig 3: View Of Counter-Holding The Crankshaft

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

NOTE:

Check the temperature with the digital thermometer VAS 6519 when heating the new spur gear.

When the temperature reaches 200 °C (392 °F), there are about four seconds to position the spur gear on the crankshaft.

A higher temperature increases the amount of time available for positioning (220 °C (392 °F) = approximately six seconds).

Make sure the crankshaft pins are clean.

CAUTION:

Do not exceed the maximum temperature of 240 °C (464 °F). Otherwise the spur gear will discolor and possibly become distorted.

-- Lay the entire surface of the new spur gear on a commercially available hot plate and heat it to at least 200 °C (392 °F) (maximum 240 °C (464 °F)). The coating faces upward.

Fig 4: View Of New Spur Gear On A Hot Plate

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

There is a risk of burns. Wear suitable protective gloves during the rest of the procedure.

-- After the temperature is reached, remove the spur gear from the plate with pliers as illustrated.

Fig 5: Remove The Spur Gear From The Plate With Pliers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Make sure the splines on the spur gear are not damaged.

-- Quickly slide the spur gear by onto the crankshaft pins as far as the stop. Use the oil seal driver 10-203 for assistance and do not tilt the gear.

Fig 6: View Of Oil Seal Driver 10-203

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Allow the spur gear cool a few minutes.

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the balance shaft module. Refer to BALANCE SHAFT MODULE .

-- Install the belt pulley side sealing flange. Refer to SEALING FLANGE, BELT PULLEY SIDE .