Crankshaft Gear/Sprocket: Service and Repair

Spur Gear, Removing from Crankshaft and Installing

Special tools, testers and auxiliary items required

• Pulling fixture (10-203)

• Puller (T10392)

• Pressure piece (T10392/1)

• Thermometer (VAS 6519)

• Protective gloves

• Commercially available hot plate

Spur Gear, Removing from Crankshaft

- Remove belt pulley side sealing flange. Refer to --> [ Sealing Flange, Belt Pulley Side ] Service and Repair.

- Remove balance shaft module. Refer to --> [ Balance Shaft Module ] Balance Shaft Module.

- Insert thrust piece (T10392/1) in crankshaft pins.





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





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





New Spur Gear, Installing

• Check temperature with the thermometer (VAS 6519) when heating the new spur gear.

• When the temperature reaches 200 °C, 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 = approximately six seconds).

• Make sure the crankshaft pins are clean.

CAUTION!
Do not exceed the maximum temperature of 240 °C. 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 (maximum 240 °C). The coating faces upward.





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

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





• 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.





- Let spur gear cool a few minutes.

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

- Install balance shaft module. Refer to --> [ Balance Shaft Module ] Balance Shaft Module.

- Install belt pulley side sealing flange. Refer to --> [ Sealing Flange, Belt Pulley Side ] Service and Repair.