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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: dieselherb1 on February 20, 2011, 05:12:19 pm

Title: Solid flywheel on AHL, now starter won't engage
Post by: dieselherb1 on February 20, 2011, 05:12:19 pm: I put a 1Z-AHU flywheel on a AHL engine mounted starter(engine and trans on floor) connected battery starter would spin engine fine. So I tried another starter I have(same style snub nose) won't engage flywheel. I noticed the trans has a bushing in the housing like that of the 1Z-AHU trans their starters have a long nose like the older engines. Can't tell if the starter gear is going too far(past ring gear) or not far enough. Or do I need to use the 1Z-AHU starter?
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: the caveman on February 20, 2011, 06:41:18 pm: This a complete guess, but isn't an ALH flywheel much deeper than an 1Z/ AHU. The original ones were damped thick while the older ones were just regular type. The starter gear could be going past the ring. You may need to get ah ALH replacement flywheel.
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: Quantum TD on February 20, 2011, 07:18:58 pm: The flywheel are completely different AFAIK. The ALH uses a dual-mass flywheel. When people talk about the conversion, they use a Corrado G60 Flywheel on the assembly.

Valeo makes a kit that's really nice that's got everything you need. They run about $400. Pricey, but nicey.
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: dieselherb1 on February 20, 2011, 07:31:10 pm: Okay but how is the G60 same-different as the AHL or 1Z. As I said earlier it worked fine till I removed one to try the other. I noticed one starter(one that worked) had a cap on the end of gear( not now) I'll try and find that cap. I was thinking one or more of my 96-97 Passats had starters with long noses, am I dreaming?
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: nathan_b on February 23, 2011, 07:00:03 am: just search the part numbers on google and use the starter that matches your a manual alh. That is the starter that will work with either a stock dual mass flywheel or a g60 solid flywheel. It's a tried and true combo.
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: dieselherb1 on February 24, 2011, 06:17:54 pm: Got it working. Two things, there was a steel cap on the gear nose that was missing and starter needs to be as far toawards the flywheel before tightening.
Title: Re: Solid flywheel on AHL, now starter won't engage
Post by: nathan_b on February 25, 2011, 05:06:01 pm: did you pin the starter drive gear AGAINST the flywheel face by tightening the bolts without the starter properly positioned or something?