komische startprobleme | Posts 32+

@Julian

Unfortunately, no luck.

joergs wrote:

Now, during the disassembly, I noticed that the starter ring gear on the flywheel is in very bad condition.

Approximately several teeth are missing, covering about 90 degrees. Some have been missing for a long time, while a few are newer.
"While I don't know of any other sources for flywheels, doesn't this type of damage suggest a very high mileage (>300,000 km) or extreme stop-and-go driving, or even rough handling of the vehicle?"

Or is such tooth loss normal over time ?

'Ulf, I don't know! On the other hand, if the engine has been having this starting problem for a while, then the tooth loss would make sense. After all, my organ (likely referring to a specific part or process) also caused tooth loss. Theoretically, according to the documentation, the starter ring gear is available as a separate part, so it's definitely replaceable due to expansion and contraction. Maybe someone has already replaced it... (and perhaps installed one from the aftermarket). The condition of the keyways on the connecting screws between the engine and the transmission would support this.'

It's a bit embarrassing to constantly be bringing up new things. But on the other hand, if the machine is completely new again, except for the charger and battery, then at least it's a fresh start. And I think that will probably be the end of it.

Luckily, it seems I haven't been affected by the fraud with my 'Pöl-Mobil'!!!!!!!!!

joergs wrote:

Because of my organ playing, he also experienced tooth loss.

Okay... have you been able to hear or feel the teeth falling out each time?

'I'm hearing some strange noises coming from the starter area. It's hard to say exactly what's happening: it started making a grinding noise when 3 teeth were missing. And if there's a gap with 4 or 5 teeth, the starter motor seems to be spinning freely or making strange noises (like scratching on the broken tooth surfaces). I'll take a picture this weekend! Maybe that's what's causing the inconsistent starter motor speed...'

Okay, now that I finally got a flywheel from VW... , I installed the engine again today. Hats off to the mechanics at VW Group. I've seen a lot of skilled work, but an engine installed in this orientation is probably the 'best' I've ever seen. But never mind. After a lot of fiddling and wiggling... it's in and bolted to the transmission, and almost completely finished. It's a shame I had daughter-sitting duty this afternoon, otherwise it would be completely finished and would probably have 'fired up' for the first time. Unfortunately, I have to go to my mother-in-law's tomorrow and therefore can't continue working on it. Well, I have vacation starting on Wednesday, and if everything goes according to plan, I'll drive the car to the customer on Friday afternoon as Santa Claus.r.

I'm really excited to see how the engine starts and runs... I'll have pictures of the timing gear next week. It seems like the block is okay. At least, the cylinder bores are okay; they have no scratches, and there's no lip felt on the piston at the top dead center. It looks like the engine has already been overhauled. The oversized pistons suggest that. There's not much left to explain the lack of compression. I suspect 'sluggish' hydraulic lifters. I'm going to keep the old engine (it would cost €300 for scrap metal) and rebuild it, so I'll have a spare for my old car (just in case ).

December 22, 2004, 4:37 PM.

brummmmmmmmmmmmmmmmmmmmmmmm

Okay, it's running again. Tomorrow, I'll finish the coolant circuit, re-install the end cap, and attach the bumper.

joergs wrote:

22.12.2004 16:37 Uhr. brummmmmmmmmmmmmmmmmmmmmmmm yeah, it's running again. Tomorrow, I'll complete the cooling circuit, re-install the end cap, and attach the bumper

.
Clean

Hopefully, the owner will recognize and reward your efforts accordingly...

I think so... after all, he saved a significant amount of money on parts alone compared to Volkswagen... and he also had my 96kW Passat as a workshop loan car.

Okay, quick update: I haven't had much time lately. It's been quite hectic between Christmas and New Year's, and the first few days of the new year.

Okay, here's the translation:

'So, the A4 is running again and was returned to its owner on December 24th. He was very surprised, as he wasn't expecting it to be ready so soon. The A4 then dutifully and without any issues completed the trip to 'herrchen's' parents (near Berlin). Between those dates, the car had already accumulated about 800 km. 'Herrchen' then suddenly complained about a lack of power. I was able to quickly resolve this misunderstanding using a ULF diagnostic tool. It showed 108 hp, which is 2 hp less than the standard output, likely due to a slightly delayed fuel injection start, which I think is acceptable. The perceived loss of power probably came from the fact that the owner was used to the higher power output of my 96 kW PD Passat, which he had as a 'loaner' car. However, 'herrchen's' driving style was impressive.' 'It doesn't bother me too much. It's running around 2000 RPM, sometimes up to 2500, but no more than that. I suggested to the owner that I take the car on a trip of about 2000-3000 km. I was already on a work trip with it last week, covering another 800 km. According to Ulf's dyno test, it now has 114 horsepower, which I think is perfectly fine. Overall, I'm quite satisfied with the modifications so far. The engine is running, it's not consuming any oil, and after just under 2000 km, it's producing its full power. All in all, I think everything is in the green. Yesterday, I did the first oil change and re-tightened the screws on the transmission flange and the engine mounts.'

edit: oh yeah, and I forgot something: at the request of 'the owner,' the A4 also got a 'new' turbocharger (if you're going to do it, do it right ). I had the turbocharger replaced at Schlütter Turbochargers, just around the corner from me (www.turbolader.com). I haven't experienced anything so nice and competent in a long time. I was also surprised by the price: about 600 euros for a completely overhauled, calibrated, and adjusted (keyword: minimum flow) turbocharger from Garrett, including a 2-year warranty. I don't think you can complain about that!