Crankshaft Sprocket: 1Z Replacement

Hello there,
I haven't found any posts about the following error here yet (or I haven't searched thoroughly ).
(G3, year 1995 / 1.6L engine / 208,000 km)

1.
The engine is difficult to start or doesn't start at all.
2.
If it actually runs: Continuous acceleration is acceptable, but taking your foot off the gas results in extremely heavy soot buildup and a loss of power.

Cause (after a long search - who even thinks of such things?!):
The sprocket on the crankshaft is worn and has approximately 1.5 mm of play.

Affordable solution: Remove the ridge on the shaft and install a new sprocket (approximately 20 €).
It took me just under 4 hours of work, including enjoying 3 bottles of delicious Kölsch.
Of course, I replaced the timing belt and tensioner pulley at the same time.

The expensive solution was deemed impractical due to a lack of resources and expertise; in fact, it would probably have been no more expensive than an entire ATM.

According to a friend who is a car mechanic, this is probably a typical problem with TDI engines.

That's it, maybe someone will find it useful someday.

Snowman.

The problem is with the screw. An insufficiently strong screw (grade 8. was used. Therefore, the screw should be replaced and properly tightened (90 Nm + 90°) every time the timing belt is changed. Ensure a perfect contact surface on the flange of the screw/gear. If the surface on the crankshaft is damaged, it can be reworked while the engine is installed.


best regards, robert

Schneemann wrote:

Hello there, I haven't found any posts about the following error here yet (or I haven't searched thoroughly ). (G3, year 1995 / 1Z / 208,000 km)

You should be able to find a lot of information here!

"Enter 'crankshaft bolt 1Z' and check the box that says 'search for all words'. You'll find everything important. Instead of '1Z', you can also try 'AAZ' - the engine has the same problem as early 1Z engines."