TDI crank sprocket upgrade.

[mzak88]

Haven't done it yet... Anyone have any luck doing this in car? I've searched but not found anything but talk on the subject. I would love to be able to pull crank, but I need my car as a DD.

[libbydiesel]

I have a jig that I use to do it with the engine in the car.  I've updated quite a few.  Probably easier to pull the crank than it is to get the car to Arizona, tho...

[mzak88]

Is this using a broach?

[libbydiesel]

Yes.

[mzak88]

Got brave today....
Involving die grinder, brand new file, Prussian blue, 2 cups coffee, 2 hours.
Managed a beautiful fit of my TDI lower sprocket. Slight interference fit and all. Thankful I went for it after pulling old lower cog.

[bbob203]

Got brave today....
Involving die grinder, brand new file, Prussian blue, 2 cups coffee, 2 hours.
Managed a beautiful fit of my TDI lower sprocket. Slight interference fit and all. Thankful I went for it after pulling old lower cog.

prussian blue? I hope the 88 in your screen name is the year you were born in and not what I think it is.

[Gizmoman]

Very good - some well earned peace of mind.
Hopefully you installed a new bolt and torqued it to spec as well.

[theman53]

Prussian blue is a high spot indicator.

[bbob203]

http://en.wikipedia.org/wiki/Prussian_Blue Glad it's not this.

[mzak88]

Yep. new bolt, timing belt, tensioner etc...

[DanV990]

http://en.wikipedia.org/wiki/Prussian_Blue Glad it's not this.

Not that wiki link.

This wiki link
http://en.wikipedia.org/wiki/Prussian_blue
By machinists and toolmakers

Prussian blue in oil paint is the traditional material used for spotting metal surfaces such as surface plates and bearings for hand scraping. A thin layer of non-drying paste is applied to a reference surface and transfers to the high spots of the workpiece. The toolmaker then scrapes, stones, or otherwise removes the marked high spots. Prussian blue is preferable because it will not abrade the extremely precise reference surfaces as many ground pigments may.

[mzak88]

http://en.wikipedia.org/wiki/Prussian_Blue Glad it's not this.

Not that wiki link.

This wiki link
http://en.wikipedia.org/wiki/Prussian_blue
By machinists and toolmakers

Prussian blue in oil paint is the traditional material used for spotting metal surfaces such as surface plates and bearings for hand scraping. A thin layer of non-drying paste is applied to a reference surface and transfers to the high spots of the workpiece. The toolmaker then scrapes, stones, or otherwise removes the marked high spots. Prussian blue is preferable because it will not abrade the extremely precise reference surfaces as many ground pigments may.

http://en.wikipedia.org/wiki/Prussian_Blue Glad it's not this.

Not that wiki link.

This wiki link
http://en.wikipedia.org/wiki/Prussian_blue
By machinists and toolmakers

Prussian blue in oil paint is the traditional material used for spotting metal surfaces such as surface plates and bearings for hand scraping. A thin layer of non-drying paste is applied to a reference surface and transfers to the high spots of the workpiece. The toolmaker then scrapes, stones, or otherwise removes the marked high spots. Prussian blue is preferable because it will not abrade the extremely precise reference surfaces as many ground pigments may.

http://en.wikipedia.org/wiki/Prussian_Blue Glad it's not this.

Not that wiki link.

This wiki link
http://en.wikipedia.org/wiki/Prussian_blue
By machinists and toolmakers

Prussian blue in oil paint is the traditional material used for spotting metal surfaces such as surface plates and bearings for hand scraping. A thin layer of non-drying paste is applied to a reference surface and transfers to the high spots of the workpiece. The toolmaker then scrapes, stones, or otherwise removes the marked high spots. Prussian blue is preferable because it will not abrade the extremely precise reference surfaces as many ground pigments may.

That says it best. 

[zagarus]

nice job on the TDI crank sprocket! In car too nice!

[mzak88]

Easier than you think, had my car up high on 6 ton jack stands & made myself comfortable. Work slow & carefully. Just a flat spot. Last few thou going REAL slow, light pressure on new file.