Sorry,
I only now found the time to respond.
How about this, why don't you waste your time "proving" that the standard keyway and unclutched alt pulley don't increase the odds of crank nose/sprocket failure. Maybe VW just updated the designs because they were bored?
I have no way of proving that without running an engine on a dyno for 500+ hours of constant abuse and HOPE that it would replicate a failure scenario.As for WHY VW updated the design of the keyway? Maybe because they updated the design of the entire bottom end running less accessories on a serpentine set up and more on a toothed belt set up?
That would be downright childish and a waste of my time and money.
No need to waste your time and money then.A simple phone call would have fixed that and they are currently out of stock of said item :wink:
Why do all VW factory rebuilt 1.9 IDI motors come with the updated crank nose and sprocket? Did they replace all of the crankshafts as a fashion statement?
And yet they went into chassis's with non clutch alternator pulleys.Apples to Oranges comparison.I am not talking about the crankshaft snout nor do I care about it.
Well, I guess that's half the point that has been made. VW did the equivalent of double pinning the crank by updating the sprocket keyway and yet did so without the effect of weakening the nose that double-pinning would have.
What is your explanation for the massively increased proportion of crank nose/sprocket failures with the 1.9 idi motors as opposed to the 1.6 idi motors which otherwise share the exact same crank nose and sprocket interface? How do you explain the similarly proportional decrease in failures in engines fitted with the updated crank sprocket and freewheel pulley?
"proportional decrease". "massively increased".You speak as though you are the voice of millions of IDI/TDI users around the globe.
I have had a brand new AAZ crate motor from VAG in my warehouse and the alternator pulley was no different than the aluminum unit I sell.Infact spend 5 minutes on ebay and you will see that most of the TDI's sold in Europe came equipped with a non clutch alternator pulley and these ranged all the way up to 2.5 TDI's!
http://cgi.ebay.de/Lichtmaschine-VW-Passat-3-TDI_W0QQitemZ370101455428QQcmdZViewItemQQptZAutoteile_Zubeh%C3%B6r?hash=item370101455428&_trksid=p3286.c0.m14&_trkparms=72%3A1229%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318http://cgi.ebay.de/Lichtmaschine-VW-T4-Transporter-LT-2-5-TDI-90A-NEU_W0QQitemZ370168078121QQcmdZViewItemQQptZAutoteile_Zubeh%C3%B6r?hash=item370168078121&_trksid=p3286.c0.m14&_trkparms=72%3A1229%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318http://cgi.ebay.de/lichtmaschine-v6-tdi-akn-vw-passat-3b-3bg-audi-a4-a6_W0QQitemZ180335515977QQcmdZViewItemQQptZAutoteile_Zubeh%C3%B6r?hash=item180335515977&_trksid=p3286.c0.m14&_trkparms=72%3A1229%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318I have requested from 4 friends who are VW/Audi certified tech's a TSB from VAG stating that they have updated all non clutch alternator on TDI motors to clutch units AND they have updated the crankshaft gears.None of the 4 could provide me a TSB with anything even close.I know you run a business and I know you are just trying to get your point across but understand my point of view.If Volkswagen saw this as a serious issue they would have recalled all motors and fixed the issues like they have done in the past with other engine models and no offense but I would trust a VAG Engineer over you :wink: .
Unless you can show me a TSB from VW/Audi stating otherwise then you are simply drawing your own conclusions based on observations rather than facts.
I'm curious why the pulley in the posted setup is deemed better than the stock AAZ pulley. They both appear to be similar in mass and both are harmonic dampening pulleys. I would add that the later 1.6 motors also had dampening crank pulleys with the v-belt system.
Andrew
Nowhere did I deem the 06A pulley "better" at all? The 06A pulley is easier to source new and has a smaller diameter than the AAZ unit.FWIW I use the AAZ pulley on my own personal motor....
The fact that one of the participants in this discussion has a vested commercial interest in the outcome is new information... cool !! :wink:
Of course I would have a vested commercial interest.How can I not?It is a product I developed and I stand behind it like all the other products I develop.Lets be a little fair shall we? If you were in my shoes you would be doing the same.How would you feel if a customer that bought a product from you told you that your product was in laymans terms "***".There have been crankshaft snout failures all across the VAG board and most are not even on diesel motors!!
One of the services that my engineering firm offers is the ability to machine ANY part to within 0.0001".If I wanted to integrate a clutch pulley into the set up I would have and still can but the reality is that there still is not enough evidence TO ME that a non clutched alternator pulley will cause catastrophic engine failure.
i was just alittle confused why a "great" seller like INA (wizard of od) was posting this set up all over the diesel forums without mentioning that it would still cause crank failure.
Why would I mention that my set up would cause crank failure when that is simply
False and UNPROVEN.
secondly, his customer service abilities make me question his mechanic abilities or even knowledge.
:roll: ....and then people wonder why I write FAQ's/tech threads.Please do not ever question my mechanical ability as I find that rather insulting especially on an open public forum!
on the bottom is the long slot for the screw to keep it adjusted.
The Screw does not keep it adjusted....the screw FIXES the alternator to the bracket.The belt is tensioned by the spring and then when the belt is tensioned you tighten the screw.So how does the screw or spring provide tension to a FIXED system?
Simple answer - it does not.
I would have sent out the right spacer right away and let her keep the old one and gave a discount on the belt too. but that's just me.
I asked both Kevin & you to give me a measurement!!
I am still waiting for you to provide this which you have not done.I have been NOTHING BUT cooperative in this matter....I am not sure what more you want me to do?
I cant send you a correct spacer if I do not know which crankshaft gear you have and I am certainly not going to let you keep a part that you do not need.They are about 4 different versions.
Look it is clear alot of us got off on the wrong foot and I am here trying to correct this but some of you are not making this easy.I apologise if I am coming off to strong but I feel as though my posts are falling on deaf ears.