aaz crankshaft keyway question

[95gltd]

Hi all

Long story short 1 night when i started my 95 td it idled fine but lacked power wouldn't rev out. Thought it was a fuel problem rebuilt injectors as the spray pattern was bad to no aveil, but now i found what i think is bad news.

I took the crankshaft pulley off. I believe it is the newer bolt 12 point 19mm. It had a little dot on the end. The key on the crank gear and gkeyway on the crank are not the same size. if i put the pulley on without the bolt it will move roughly 1/8 inch clockwise and counter clockwise. If i put the bolt on and tighten it up you can't move the pully anymore. I assume that there should be no movement even without the bolt? Should be a snug fit?

Didn't really notice any pulley wobble idling. Keyway looked nice 1 1/2 yrs ago when i got the car and installed a new t belt. Been about 50K. I installed the ratchet alt pulley too at that time. guess it didn't save anything.

I have heard some tdi cranks will fit. What is the cost of a tdi crank? Would i need a balancer to go along with the tdi crank gear? The car is an a/c model so would i need any other tdi specific parts?

Thanks

[burn_your_money]

There's a guy on here (Andy something or other) that does crank repairs. I think he is Kitchener area. I believe he charges in the $400 neighborhood and the engine and crank stay in the car

[95gltd]

darn to bad i'm in quebec.

[burn_your_money]

There's probably some people in Quebec that can do it as well, maybe try posting in the french section

PS You should add quebec to your profile

[QuickTD]

Andy2 has a setup for machining the crank nose in the car, he's done quite a few. He's located in Bowmanville, Ontario, just east of Toronto. Still not very close to Quebec...

 I can weld up and remachine the crank to take a TDI crank pulley, but you have to take it out and send it to me. Cranks are heavy, and therefore aren't very cheap to ship, about $80 each way (expresspost) from atlantic canada as I recall. Might be a bit cheaper from Quebec. The job costs about $150. I can also provide the TDI pulley (genuine VW) for another $70 or so.

 Any good automotive machine shop should be able to do a similar repair job, I don't have any special equipment, just a lathe, mill and a TIG welder. I would suggest you pull the crank, get a AHU TDI crank pulley and check out a few local machine shops.

 The TDI crank is also an option. It's a bolt in, all you need is the crank and the timing pulley. You'll also need rod/main bolts, pressure plate bolts, pan gasket and rod/main bearings to complete the job.

[95gltd]

update

something doesen't add up here. I measure the key on the crank sprocket
~ 7.70 mm
keyway measures 7.85mm with a digital guage.

Not really any loose. Yet if you put the pulley on it rockes back and forth with your hand untill you sinch up the bolt with a ratchet.

Bought a new bolt. Gonna put some Jb weld in there for good measure and some loctite on the new bolt and trq it to spec. Back to the drawing board.

Took the bolt off with an impact didn't seem to be very tight maybe the bolt worked itself loose. If i remember right the guy that did the t belt 1 1/2 ago just put the old bolt back on with an impact.

[jimfoo]

Mine was a *** to get off, even with an impact. The previous owner shouldn't have reused it as it's a stretch bolt. Maybe that's why it wasn't too tight.

[95gltd]

it came right off with the impact on setting 1. Didn't seem tight at all. I knew that the guy that did my timing belt job reused the bolt. I found out after he didn't know much about diesels. At the time i didn't know it was a 1 time stretch bolt.

The vw shop i got the bolt from said to torque it to 66 ft/lbs then go 1/4 turn after. This sound right?

[Sandy]

Allmost 2 years ago I went through the same thing. At that time no one here in  Halifax would repair a crank and the price of a new one was out of the question.

QuickTD said he repaired these and showed pics of the process. So I pulled the crank, built a shipping crate and sent it away.

From Halifax, insured express post to Dashwood and back in 5 days. Shipping, insurance and repair the crank was $310.

He does an awesome job and will  reccomend him every chance I can.

[QuickTD]

At very least I would use a new pulley. The key is no doubt worn from being loose. I would use loctite sleeve retainer (green) on the pulley and key rather than JB weld, the compressive strength of the loctite is better. Keep in mind that these things hammer themselves loose when they are made of steel, so most glues/plastics don't help much...

 If anyone from the east coast ever decides to send me a crank it would be worth your while to get in touch with "Sandy" and ask to borrow his crank shipping crate. It's a beautiful piece of furniture.

[95gltd]

the keyway on the crank is .2 mm wider than the key.

I'm waiting to get the pump verified before putting this thing back together again.

I debated buying a newer first gen TDI, but the body is immaculate on my golf. No rust in the floor,rocker panels. Had it painted 2 years ago and its been undercoated all its life. I looked at a few 97-99 tdi's and the bodies were kinda rough.

[95gltd]

Ended up my injection pump was finished.

Had it redone By Tintin onthis board. I couldn't believe the price he rebuilt it for. Less than half of what Bosch wanted before tax !!!!