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Oil pump and balance shaft replacement on 2004 2005 VW Passat TDI part 2

Time:2015-08-16 22:37Turbochargers information Click:

VW PASSAT Shaft balance oi

Part 2 - oil pump balance shaft assembly replacement on BHW engine Passat TDI - part 2

difficulty: 4/5
back to 1000q: B5.5 2004 2005 VW Passat TDI "how to" index
back to part 1 - oil pump balance shaft assembly replacement

Removing the engine oil pan

(engine was out of car for illustration)

Remove the vac reservoir bracket/foam insulation (2x 8mm allen head bolts) pictured previously if you haven't removed it yet.  

Remove the oil pan (2x 16mm bolts and 18x 5mm allen head bolts, some indicated below).  Use the 5 mm long ball end allen (metalnerd MNQ6H5) on the 2 allen bolts by the transmission.  The transmission is normally in the way so you have to get them at an angle (reason for using ball end allen) or use some extensions and joints.  The oil pan should come off easily so if it's still stuck, check for missed bolts.  If you're sure it's free, gently tap around the edge of the flange with a block of wood.  Once it's off, cover the exposed engine parts and use a razor/green scotch brite to clean the sealing surfaces as much as possible.

Remove the front oil seal flange (6x 10mm bolts, pic is from an earlier step).  Once it's off, put a few drops of PB Blaster or other penetrating lubricant around the edges of the oil seal and let it penetrate for at least a minute.  This will make seal removal much easier.  Press out the old front crankshaft seal from the backside with a socket of the appropriate diameter wrapped in tape to prevent scratches to the sealing surfaces.  Do not install the new front seal.

Replacing the balance shaft module and oil pump

Remove the lower plastic chain cover (2x T20 torx screws, white arrows).  Note the green arrows for a later step.

Loosen the small oil pump sprocket bolts (4x 6mm allen, one of the bolts pictured already has an allen bit on it).  Put the crankshaft sprocket back on (with crank yank attached) to counterhold the chain and small oil pump sprocket.

Remove the oil chain tensioner, the green arrows in the previous picture (2x 8mm triple square and 1x 6mm allen head bolt).  Mark the direction of the oil chain if you are going to reuse it and remove it along with the small sprocket (since you loosened the bolts earlier).  These parts will not be reused on the new assembly.

Now prepare to remove the oil chain's crankshaft sprocket.  The service manual shows use of VW puller T40001 with claws /3 and /5.  Others have suggested and I suggest using VW puller T10392 as shown below but it needs to be ground down a little to fit correctly.  The advantage is that it pulls much closer to the base of the sprocket, has 4 arms instead of 2, and it's less likely to shatter the sprocket and make it difficult to remove.  You could use a 3 arm puller but this tool has 4 evenly spaced arms and is easy to use.  If the sprocket shatters, remove the nearest crankshaft bearing main cap (#1 cap, 2x 17mm bolts) to get clearance and knock off the sprocket from behind.  The crankshaft cap bolts are single use only bolts so if you remove them you must replace them.

 

Squirt some PB Blaster or other penetrating lubricant at the base of the sprocket and clean the sprocket snout to help avoid scratches.  It needs time to penetrate and the sprocket is so tight I'm not sure it can penetrate at all.  If not, it should help lube the sprocket as it comes off.  Take this time to modify the puller to fit correctly.  

The pegs on puller T10392 are round.  Slightly grind the inside face of the pegs to clear the sprocket holes as pictured below and by the red line.  Don't remove too much!  Once that's done, squirt some more lube around the sprocket.  

Insert the base plate that came with the tool into the crankshaft bolt hole and put the puller on top of that.  As you tighten the bolt, tension will increase until the sprocket comes off.  Tighten it a few turns, wait, then tighten it a few more turns.  You can gently tap the tool's bolt with a rubber mallet to help shake the sprocket off.  Don't try to pull it off too fast, let the tension come down slightly before tightening it more.

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