Crank pulley problem-need help

[albinfo]

Hi guys,

I checked at this forum and found several topics similar to mine, but I belive it has some differences, so I think I might ask if anyone have an opininon on my case?

I have a golf III 93 GL with TD engine. I noticed that the Cranshakft Pulley(main pulley that connects directly to the Crankshaft) was shaking a little but after a check to a private mechanic he said it was nothing, mabye the central bolt or the pulley needs replacement. First I bought a new bolt. No change. Then I found another pulley but replacing it did not solve the problem either. I took a second opinion from another mechanic and now there is a doubt of a Crankshaft problem, which I consider very serious sience this would mean opening the engine - very risky and very expensive. I really do not want to open the engine? I would prefer a solution without touching the Crank. I am really worried and do not know what to do.
If it is the crank that has been deflected, wouldn't that effect the overall engine performance? So far (beside a whistle that comes time to time from the main belt that passes through the pulley) I have not noticed any other problems, espetially with the engine.

Please give me an opinion

thanks,
Albi

[MacGyver]

First off, put your location in your profile so someone may be able to suggest local help.

Second, how many miles on the engine?

Third, if it's your accessory belt pulleys that are shaking, that could mean they aren't perfect, or your timing belt pulley is no longer sitting correctly mated.
You will need to remove the crankshaft timing belt pulley and closely inspect the crank nose & mating surface inside the pulley for galling or wear of any kind. Especially the key area.
Be prepared to repalce the pulley & bolt at the very least. The pulley isn't expensive.
If the crank shows any wear, it NEEDS to be repaired or you risk failure, as you've probably read in other threads on here.

[albinfo]

First off, put your location in your profile so someone may be able to suggest local help.

Second, how many miles on the engine?

Third, if it's your accessory belt pulleys that are shaking, that could mean they aren't perfect, or your timing belt pulley is no longer sitting correctly mated.
You will need to remove the crankshaft timing belt pulley and closely inspect the crank nose & mating surface inside the pulley for galling or wear of any kind. Especially the key area.
Be prepared to repalce the pulley & bolt at the very least. The pulley isn't expensive.
If the crank shows any wear, it NEEDS to be repaired or you risk failure, as you've probably read in other threads on here.

Thanks for the answer.

I am located in Albania, Europe (which I do not think any of you guys visited    ) this is why I did not put on my location. I was recomended this forum form a friend of mine.

My engine has 160 000 km. The only pulley that shakes is the Crank one. As I mentioned earlier, I already changed the bolt and the pulley with no result. I have not inspected the crank nose, but I remember the mechanic turned the machine on when the pulley was off, and you could notice that the rotation of the crankshaft nose, was not very steady. Is it possible that it might be deflected (just the nose)?

Thanks again,
George

[asau]

the crank has a rectangular shaped key in it, crank vibrates (crank bolt noe being replaced) the key loosens causing the harmonic balancer to vibrate. you can fix it by using a TDI crank sprocket. the TDI sprocket uses a "D" shaped key. that is the new problem, your old crank is rectangular and the new pulley is "D". you might be able to take the car to a machine shop and get the to match the new pulley to your old crank by grinding off the extra material on your crank to make the TDI pulley fit. this is possible to do with the engine installed just a major PITA

[QuickTD]

Third, if it's your accessory belt pulleys that are shaking, that could mean they aren't perfect, or your timing belt pulley is no longer sitting correctly mated.
You will need to remove the crankshaft timing belt pulley and closely inspect the crank nose & mating surface inside the pulley for galling or wear of any kind. Especially the key area.
Be prepared to repalce the pulley & bolt at the very least. The pulley isn't expensive.
If the crank shows any wear, it NEEDS to be repaired or you risk failure, as you've probably read in other threads on here.

My thoughts exactly. If the end of the crank is worn (very common problem) the crank needs to be removed, welded up and remachined.

[albinfo]

My thoughts exactly. If the end of the crank is worn (very common problem) the crank needs to be removed, welded up and remachined.

Hi guys,

This week-end I took the machine to another mechanic. His opionion was that the crank nose was a little deflected, but I could go on like that as it should not be serious problem. That did not convince me. He just took the pulley off, turned on the machine and looked at the crank while rotating. He did not take the sprocket off, have a look at it and mabye put a new one to test it.
Then I took the car to the local VW servis. They did the same examination (without removing the sprocket) and told me that I should replace both, the Pulley and the sprocket and in addition to that, I should take of the crank, weld it up and machine it, since it might be consumed???
I am really confused now. None of the above did bother to take off the sprocket and check it. What do you think about it?

[vixentd]

you have a 1.9 which is plaqued with this problem.  
1.  Check the idler arm for the serpentine belt to make sure it is not the problem.  These must be replaced as they will shake hte serpentine belt.

2.  The problem is not the puley but the crank shaft sprocket. THe pulley has a key way which wears and also wears out the crank grove for the keyway on the sprocket.
3.  A new crank shaft sprocket will not work, is the crank is damaged as it must fit on perfectly.
4.  To fix, use a 1999 or newer crank, or have yours welded and then ground down to take a new style crank shaft pulley. ( it has a D at the end instead of a grove.)
5. Some shops have ground the crank down on the car and slid the new style pulley on.  NOt sure how accurate you could get though?

MAKE SURE IF THE CRANK SHAFT SPROCKET COMES OFF, A NEW STRETCH BOLT IS INSTALLED AND TORQUED TO THE CORRECT SPECS PLUS THE ADDITIONAL ROTATION.

[albinfo]

4.  To fix, use a 1999 or newer crank, or have yours welded and then ground down to take a new style crank shaft pulley. ( it has a D at the end instead of a grove.)

Can you please specify if it is the pulley or the sprocket having the D? I am asking because I want to know if I should change both Pulley and Sprocket?

MAKE SURE IF THE CRANK SHAFT SPROCKET COMES OFF, A NEW STRETCH BOLT IS INSTALLED AND TORQUED TO THE CORRECT SPECS PLUS THE ADDITIONAL ROTATION.

DO you meen that this bolt should be screwed until a certain point, not more or less? How can you measure that?

Thanks,
Albi

[vixentd]

You must buy a new style crankshaft sprocket that will then have a D on the end.  1998 or newer diesel crank.

Yes you use a torque wrench and tighten to the ft lbs,and then 1/4 more with a new stretch bolt.

[albinfo]

Does anyone knows the part number for this crankshaft sprocket? I made a search but found several part numbers and I'm not sure which is the right one.

Yes you use a torque wrench and tighten to the ft lbs,and then 1/4 more with a new stretch bolt.

I'm sorry, but I am from Europe and my english is not that good. Would you mind explaining in other words how to use the torque wrench in this case and what does that "1/4 more" means.

Thanks a lot,
Albi

[asau]

1/4 more is what the bently manual says, 66 foot pounds then you also need to turn the bolt an additional quarter turn

[Josh]

1/4 more means 90 degrees more, or 1/4 of a full rotation.  So first, you use a torque wrench to tighten the new stretch bolt to the specified torque.  Then, you turn the bolt 90 degrees more.  In other words, you can look at the position of the handle for the wrench.  Then turn it further, such that it's end position when compared to its original position forms the letter "L".  

I hope this helps!  Good luck!

 -Josh