Crankshaft Stub Planer for 1.9 TDI ALH

Hello fellow DIY enthusiasts,

I urgently need your help with a classic problem. I just installed a replacement engine (1.9 TDI, engine code: ALH).

Unfortunately, the crankshaft pulley is now wobbling, and a newly installed oil seal has immediately started leaking again. The symptoms are: the engine runs unevenly and makes a loud clacking noise during load changes. At a constant speed between 2000 and 3000 RPM, it's quiet for a short time, but when releasing the throttle in coasting, there's an immediate metallic clanging sound. I strongly suspect that the front surface of the crankshaft is tilted or that the groove is damaged. This defect was unfortunately overlooked during the replacement engine installation. Since the car is already parked and I want to save the engine, I would need to have the end of the crankshaft faced on its front surface.

Since I only need the tool once, I wanted to ask if any TDI colleagues in the area (I live in 4225 Luftenberg an der Donau, near Linz, Upper Austria) happen to have a suitable crankshaft stub-facing cutter (and ideally the matching holder) that they could lend me for a day in exchange for a fair deposit and a few bottles of beer/a donation to the coffee fund. I would, of course, pick up the tool myself.

Thank you in advance for your help!

Best regards from Upper Austria.

I'm sorry, I can't help you with that tool.

However, I have a point to make: The oil seal is actually located on the straight section of the crankshaft and has nothing to do with whether the crankshaft is properly aligned. If it leaks again so quickly, then there's more to be done. In my opinion, simply resurfacing the component won't save the engine. Whether it's even worth saving this engine depends on the extent of the underlying damage. The noises make me fear something worse.

My guess is that the imbalance is constantly pushing the seal slightly to one side, causing oil to leak out. When I loosen the ribbed belt, the clicking noise also disappears, and I suspect that when the belt is under tension, the roller for the ribbed belt is hitting against a cover.

Raphi, a loose crankshaft pulley won't cause the crankshaft to swing in a way that makes the seal leak. The crankshaft bearings are more robust than that.
If the KW pulley is wobbling, is it properly mounted? It's likely there's a keyway connecting it to the drive shaft, and the screws might not be offset by 90 degrees, but who knows (possible installation error). I should take another look at that, and also check if the KW drive gear is wobbling.
Was war die neue Hauptschraube, und wurde sie auch gemäß den Spezifikationen angezogen?
If the clicking sound disappears when the tensioner is removed, it's likely due to the tensioner itself. Could it be a faulty freewheel, a loose tensioner pulley, or a worn-out bearing in a component?
hg
Herbert.

Hello Herbert,
Haben nach den neuen Simmering wieder alles zusammen gebaut wie es sich eigentlich gehört haben auch auf die nase geachtet. Was mir halt aufgefallen ist als wir das Zahnrad von Zahnriemen runter getan haben ging es sehr schwer ab erst mit ein paar leichten Hammerschlägen ging es runter der fehler war aber schon zuvor da also haben wir nichts beschädigt. Am KRR Antrieb hätte wir alles schon getestet macht alles kein Problem. Dachte ganz am anfang das die Rolle von Kurbelwelle auf Keilriemen unwucht hat die haben wir dann natürlich auch getauscht. Hätte mir es jetzt nur so erklärt können das die Fläche von Kurbelwelle nicht mehr plan ist und durch das leichte links rechts was ja bei standgas ja 900/min sind das der simmering da nicht ganz mitkommt, weil die Kurbelwelle von so einen legendären 1.9 bekommt normalerweise nicht so leicht einen schlag. Muss aber sagen kenne mich nicht so gut aus bin kein Mechaniker mach das alles nur hobbymäßig mit 20jahren und möchte ihn vor den winter noch ohne Probleme zum laufen bringen. Also würdest du vermuten das es die Kurbelwelle selbst ist? Hätte jetzt nicht so bock drauf kurbelwelle auszubauen und von meinen alten Motor einzubauen aber wenn es nicht anders geht dann muss es so. Are there any other possible sources of the oil leak? It's leaking from a small slit located underneath the timing belt cover.
Best regards and thank you in advance.
Raphael.