Help -- Crank Position Sensor Doesn't Match on my 2004 B5 Passat TDI

I have a 2004 Passat GLS TDI
BHW Engine ...
315K miles -- been running perfect until recently
Door Tag says it was made 05/04
Car was made in Emden, Germany

Car threw : P0727 Engine Speed Input Circuit No Signal

While leaving a parking lot Car stalled & would not restart for apx 5 min after Leaving a parking lot --

After the 5 min it restart and i drove it home (pretty straight drive of apx 6 miles) I feel pretty confident it is the Crankshaft Position Senor or the Camshaft Position Sensor or both ... (I just drained the tank & replaced the in-tank-fuel pump module )


So if i am convinced it is the Crankshaft Position Sensor -- then what's the problem????


the Official Crankshaft Position Sensor part is: OEM 038907319E

Problem: The part doesn't match the original on my car !!

The OEM Part# Calls for this (look at the picture -- note the shoulder on the sensor shaft)
https://www.idparts.com/crankshaft-position-sensor-b55-p-5550.html


The actual Sensor in my car (it is original unit with 315K miles) actually looks closer to this one :
http://tinyurl.com/yb2o2cth

Notice the OEM Sensor Part# has a shoulder with an O ring at the end, while the one in my car does not have the shoulder and O ring (it is more like the second one )

The mechanic --- (some North Austin VW Specialists) are confused -- and quite frankly -- so am i ...

Any help or IDEA???

Thanks
Darryl

There are often several suppliers for parts that VAG uses, and the parts are interchangeable. I have replaced a handful of BHW CKP sensors and never ran into any fitment problems. The ones I use are black with a green o-ring, like the one pictured in the IDparts link.

You have to make certain the hole AND the flat surface of the block are clean before installing the sensor, and I put a dab of petroleum jelly on the o-ring to help in slip (almost a "snap") into place. Don't force it in with the mounting bolt.

I am a little shocked someone who you say is a Volkswagen specialist doesn't know this. It is quite common. There are probably hundreds of other parts on your car that have a replacement that is different from the one it left the factory with. Some examples off the top of my head are the valve cover (went from hex to Torx bolts), the alternator pulley (different color, bigger bearing), the glow plugs and control unit, the torque converter, to name a few. Not as many as some other models, as by the time your Passat left the factory, the B5's platform was winding down. Far more changes could be noted from the older B5s.

I assume he looked at that ... he said the Shoulder on the OEM# will not physically fit. I am going to bring it up to him ...

I Got my Car in June 2005 (Brand New) --- My car is was made either as an early 2004 (May 2004) or a late 2004 (May 2005) ... (I don't know if they list Month/Year or Year month on the door jam sticker ) ...

Anyways , my car seems to have a few unusual parts -- For instance the Intercooler tube is one for the European market (The American market part doesn't fit ) . Even the Dealer commented on that -- and was surprised to see my GLS TDI with cloth seats ...

I am thinking i have something slightly different-- maybe an early or late modification at the factory.. That is why i wanted to see if anyone else had the same experience...

I have never run into that.

The only things I have ever noticed different on the 2004s vs. 2005s: sill plate trim was deleted on 2005s, coolant fill cap, GLS got 16" wheels in 2005 vs. the 2004's Michigan 15", and the outer front bumper trim screws are the type with a separate washer on the 2005s. But there are not many 2004s anyway, it was a mid year intro for us.

Do not remember the build date on my 2004.

I have a 2004 4mo 1.8t wagon with cloth seats, the only one of its type I have ever seen too.

oilhammer said:

I have never run into that.

The only things I have ever noticed different on the 2004s vs. 2005s: sill plate trim was deleted on 2005s, coolant fill cap, GLS got 16" wheels in 2005 vs. the 2004's Michigan 15", and the outer front bumper trim screws are the type with a separate washer on the 2005s. But there are not many 2004s anyway, it was a mid year intro for us.

Do not remember the build date on my 2004.

I have a 2004 4mo 1.8t wagon with cloth seats, the only one of its type I have ever seen too.

Click to expand...

Well I think the only resolution at this point is to get the # off the existing sensor and see if we can find a match...

I will post the part# here once they get it out and give it to me

Exactly. Clean it up, a little lube, and just the right amount of pressure and it'll pop right in. Again, a VAG specialist would know this (as the gasoline engines are the same way).

Only other advice is compare the old one's length to the new one. The 1.8t is shorter but everything else is the same. I had the dealer provide me the wrong one once and I did not check it before installing it.

Well -- I thought I would put an update to this --

The position sensor model is fixed -- but the original one on the car was physically a little different than then it's direct placement from VW .. But the VW replacement worked out okay after they cleaned out the area... Kudos to MotorMania VW in Austin TX for figuring it out.

Side note -- i will post a pic of the original if you are interested