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Engine Specific Info and Questions => IDI Engine => Topic started by: boomenstein on April 27, 2015, 08:58:40 am

Title: AAZ crank Wobble. Opinions please!
Post by: boomenstein on April 27, 2015, 08:58:40 am: https://youtu.be/dt0oc9IA87M

Above is a link to a video of my wobbling crank. It doesn't look so bad with the Pulley off so just looking for opinions from anyone who has experience with this issue.

I just want to drive my car .

Should I be worried?
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vanbcguy on April 27, 2015, 11:09:53 am: That is BAD... You are not far away from having your engine ruined. Yes, you should be very very worried.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: boomenstein on April 29, 2015, 11:30:40 am: Anyone know where to get this done in Ontario?
I talked to Giles but he is not sure when the guy will be in to do it.

Would like to make it to spring Fling!
Title: Re: AAZ crank Wobble. Opinions please!
Post by: RunninWild on April 30, 2015, 05:00:37 pm: pretty standard fix is to have it machined to a TDI sprocket.

I'm about to get my block sent off for machining. Does anyone know what TDI sprocket should be used or do any of them fit?
Title: Re: AAZ crank Wobble. Opinions please!
Post by: burn_your_money on May 01, 2015, 09:55:32 am: Quote from: RunninWild on April 30, 2015, 05:00:37 pm
Does anyone know what TDI sprocket should be used or do any of them fit?

AHU or 1Z. You need a clutched alternator pulley too though. There are quite a few reports of stock TDIs failing and the clutched alternator pulley is suppose to help.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: RunninWild on May 01, 2015, 04:16:09 pm: . Would pinning the stock crank and sprocket be a better solution assuming the stock sprocket is still in good shape?
Title: Re: AAZ crank Wobble. Opinions please!
Post by: theman53 on May 01, 2015, 04:47:33 pm: I don't think so but not sure. My reasoning is you have a forged crank that is probably stronger than whatever pin you put in to it. 4 pins and the D sprocket would be best but if it is one or the other I would go with the D sprocket.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vanbcguy on May 01, 2015, 06:03:13 pm: Personally I think the pins are kind of silly. Unless they're made out of something REALLY strong they can't even come close to the strength of the original keyway. D-sprocket plus a properly torqued NEW bolt and the alternator pulley is a pretty reliable solution.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: RunninWild on May 01, 2015, 06:20:48 pm: I'll try and track down a new sprocket then.

Are alternator pullies usually interchangeable? Reason being I'll be using a suzuki samurai alternator on my AAZ. ..
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vwzzuk on May 03, 2015, 03:01:51 pm: This is the TDI sprocket I use for the crank mod: 028 105 263 D
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vanbcguy on May 04, 2015, 11:43:04 am: Any particular reason for using the Suzuki alternator instead of a VW one? Sounds like a pain...
Title: Re: AAZ crank Wobble. Opinions please!
Post by: RunninWild on May 04, 2015, 12:03:16 pm: the vw alternator sits in a location that would interfere with the steering box. The mounting kit to use the engine comes with a bracket that relocates the alternator to the the exhaust side of the engine. I imagine they went this way over the vw alternator to save any rewiring or to make parts easier to find.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vanbcguy on May 04, 2015, 09:19:11 pm: Is the alternator a Bosch, or something else?
Title: Re: AAZ crank Wobble. Opinions please!
Post by: burn_your_money on May 05, 2015, 06:58:27 am: If it's a v-belt you don't need to worry about the clutched alternator pulley. It slips enough to not cause crank issues (as the theory goes).
Title: Re: AAZ crank Wobble. Opinions please!
Post by: RunninWild on May 05, 2015, 05:10:37 pm: Well thats good to know. V belt saves the day! My machinist is going to inspect my crank and if its in good shape he said he would pin it. If it needs to be replaced were going to go with the tdi sprocket. He said hes done both repairs on AAZ's and hasnt had any problems with pins on any of his rebuilds.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: theman53 on May 05, 2015, 06:29:03 pm: I wonder how many miles some of his rebuilds actually have. I would ask for a customer reference if it were me.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: Gizmoman on May 06, 2015, 09:52:36 pm: The D is latest greatest from VW and is capable of handling more torque than the stock AAZ unit.
New bolt for sure, no lock-tite - just the spec torque (no more, no less). It's engineered to stay based on the torque and the two faces mashed together. Pins, the D, the tiny key, all play second fiddle to the mash-up so make sure the end of the crank is nice, mirror flat, and spotless - like brake cleaner clean.

I run a V belt and no troubles so far.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: boomenstein on May 09, 2015, 08:34:18 pm: Still trying to find someone to do this mod with the engine in the car, I bought a early tdi cranks and pulley. Dreading having to do the swap...it feels like it will be a can of worms opening the bottom end.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: vanbcguy on May 10, 2015, 08:57:10 pm: Changing the crank in-car is not worth it - you have to separate the trans anyhow so you might as well yank the whole shebang.

Getting the existing crank nose machined in car is something people get done however.
Title: Re: AAZ crank Wobble. Opinions please!
Post by: Gizmoman on May 11, 2015, 06:18:04 am: I know it sounds crazy but I've read some posts of guys grinding/filing the crank to fit the "D". It would take some very good eye/had control and plenty of patience. I believe someone had even used a broach and built a fixture to hold it in place (possibly it was Andrew Libby?).
http://www.vwdiesel.net/forum/index.php?topic=27450.0 (http://www.vwdiesel.net/forum/index.php?topic=27450.0)

My AAZ had a good stock pulley and crank and no signs of wear at all. I was rebuilding the engine though so I did the D mod while the crank was out due to all the horror stories.

Your original post says you just want to drive it. If I were in your shoes, I might get a new stock pulley and bolt, make sure the end of the crank was mirror, flat and bolt it on. Again, only if I was running a V-belt though.
Let us know what you end up doing.