AAZ Crank Bolt Replacment

[xsp2467]

So my crank sprocket was wobbling and I thought it was time to lift up the skirt and see what exactly I was dealing with. So I backed off the crank bolt and found an interesting discovery. I was told when I originally when I purchased this motor from a guy in Ontario that the engine was rebuilt. However he neglected to really explain why and my French was not really good enough to translate out his slightly broken English. So I bought the thing and had it shipped to California..... Anyway after I took the crank sprocket off I found the reason as to why the motor was rebuilt. The crank sprocket had already failed at one point causing catastrophic engine failure. (which is my assumption since I didn't own the motor yet) My educated guessing has told me that the machinist who did the repair job knew nothing about using a tdi crank sprocket as a replacement, so he just machined the same exact void for the key way 180 degrees out. That is not my choice for a solid repair but what am I gonna do.... Here are some pics and I was just wondering if anyone had any comments.

[xsp2467]

would it be possible for the machinist to weld up the effected area and mill the flat where the original position is supposed to be, It would just be nice for the TDC mark on the flywheel to line up with the arrow on the transmission

[burn_your_money]

The TDC mark on the flywheel will always line up with the pointer as long as you assemble the clutch/PP properly.

I would cut the flat on top of the one of notches. This way it will maximize the surface area between the crank nose and crank gear. Paying to have both of them welded up would probably be ideal.

[burn_your_money]

I wouldn't have the key cut onto one of the notches unless it was welded up. The notch with the TDI flat cut across it will weaken the interface of the TDI sprocket. 

How so? Doesn't the TDI flat completely remove the original AAZ notch?

[AudiVWguy]

Could somebody please post pictures of what the TDI version looks like? Thanks.

[theman53]

http://catalog.eautopartscatalog.com/archsoftware/europartsetc-us/wizard.jsp?partner=europartsetc&year=1996&make=VW&model=PAS-TD-001&category=A&part=Crankshaft+Gear&partnerSession=44f5b11f762627a967824a69eb988966
But it doesn't show the part your looking for with the D in it. I will take a pic of mine and post.

[theman53]

Found some on google images.