TDI - AFN-Motor, Startschwierigkeiten, weißer Rauch, Ruckeln | Posts 24+

So, the wheel was already working against the crankshaft. Judging by the appearance of the journal, planing won't help anymore; it will only flatten the front surface. The profile of the journal and the chamfer of the crankshaft seem to be worn out. And with that, a proper fit (when the screw is tightened) is no longer achievable. Friction alone is not enough.
That's a shame.
Herbert.

Even though I may be repeating myself: The groove only serves to position the timing pulley; it is held in place solely by the surface pressure from the crankshaft and the crankshaft pulley.

I've already refurbished several VW engines (gasoline, TDI, and TDI) using a flat milling cutter, and they all lasted until the car was sold and left my possession. You just need proper tools and a lot of patience.

Quote:

Even though I may be repeating myself: The groove only serves to position the timing pulley; it is held in place solely by the surface pressure of the crankshaft and the crankshaft pulley.

Rüdi, I urge you to read the link above again. First, there is no "nut" (recess) starting from size 1Z, and second, the developers explicitly mention "form closure," which I can only support based on my own experience. Holding with area pressure is nonsense in this case.
hg
Herbert.

Hi,

Since the AFN is likely not a brand new part, what's wrong with machining the front surface of the KW (king pin) flat and then using a sealant like Loctite 276 to ensure a tight fit on the surfaces outside the front surface of the KW?
The alternative would likely be to scrap the vehicle due to its age, so there's not much to lose.

Best regards, Rainer.

Sure, but it's only a temporary solution.
The milling technique works like a valve seat grinding tool for the faucet.
To achieve clean results, the workpiece must be clamped in a machine. How else can milling in a plane perpendicular to the workpiece axis } be performed with controlled tolerances?

Herbert.

Hello everyone:

Thank you for your ideas and for participating in the discussion.
This is, of course, another one of those debates. What are we supposed to do?

Yesterday, I visited my father. There, in the garage, I had stored the parts from my old AFN engine. This engine had a piston failure at approximately 260,000 kilometers.
However, the crankshaft and the timing pulley are fine.

I took the parts home and inspected them today. The timing pulley has a slight amount of play on the "good" crankshaft. I would say that the timing pulley can be rotated approximately 2-3 degrees.
I then tested the "good" (i.e., not damaged) timing belt pulley on the "defective" crankshaft at the engine, and I found approximately the same amount of play.
The only difference is that the ZR wheel fits perfectly on the "good" KW, while it doesn't sit flush on the defective KW.

In my garage, I also have a disassembled gasoline engine (type AEA). The timing belt pulley is secured there via a rectangular groove. I can also observe approximately 2-3 degrees of play there.
So, it seems the wheel will likely be held in place primarily by the flat surface. The NW wheel also doesn't have a groove and is "only" held in place by the pressure of the screw.

Regardless. I don't have much to lose. Trying it with the milling cutter is worth it.

Does anyone know how many times you can use a cutter like that?
Is it worth buying a used one?

Have a nice Sunday.

Kiko.

dieselschrauber wrote:

Hi, Since the AFN is likely not a brand new part, what's wrong with milling the front surface of the KW (crown wheel) flat and then using a sealant like Loctite 276 to ensure a tight fit on the surfaces outside the front surface of the KW? The alternative would likely be to scrap the vehicle due to its age, so there's not much to lose. Best regards, Rainer

Weicon offers various adhesives specifically designed for applications like this. I would trust them to provide a strong bond if used correctly. However, if the wheel needs to be removed, it will likely only come off with a cutting torch.

If you can find a way to plane the area, nothing bad will happen other than being able to keep the engine running. If you can't borrow one from somewhere, I would personally even go so far as to buy one myself; it's all cheaper than throwing away the engine or the car.

You can't compare that to simply milling at the faucet. With the tool I borrowed (from the company Klann), a shaft is screwed into the threads of the crankshaft, which then provides the necessary guidance for the milling tool. Then, all you need is a lot of patience and the use of cutting oil, and you'll usually be able to get it back to a point where you can drive again without worrying that the engine will fail after a few thousand kilometers.

@ Kiko:
To avoid going around in circles, what do you think about first cleaning the cutting edge of the workpiece, and then taking pictures of the front face, the flat surface, and the bevel?
Then you can see the condition.
hg
Herbert.

Hello Rüdi, hello Herbert,

"Thank you very much!"
That's exactly what's being done. I ordered the milling cutter from Dieselkontor yesterday. It will be shipped tomorrow. I don't think I'll receive it before Friday. But as soon as it arrives, I'll level the surface.

Then we'll see what happens next.
I'll get back to you with feedback and pictures.

Have a great week, everyone...

Kiko.

Dear Herbert,

I read too quickly.
Sorry.

I cleaned the stub. The bevel doesn't seem to be damaged, but the surface is definitely not flat.
When I install the newer timing belt pulley, it doesn't sit perfectly flush.

I'd be happy to take some pictures, but I won't have time to do that today.
I will set it up tomorrow.

Hello.

Kiko.

Hello everyone,

Here is a brief progress report:

I ordered the cutter for the crankshaft from Dieselkontor on Sunday, May 21st. Unfortunately, the part has not yet arrived. They are also unable to tell me when it was shipped or whether there is a tracking number that I could use to track the package. I am somewhat disappointed about this. The communication is not working at all.

Der Golf steht in der Garage und wartet. Me too...

I will get back to you as soon as there is any news.
See you later.

Best regards from Andalusia.

Kiko.

Good morning.

I'm starting to get a little nervous. No one is answering at Dieselkontor. There's nothing I can do by phone either, and besides, they're closed on Thursdays and Fridays.

I've just reviewed the website again, and I now see that they don't supply to private customers. They only supply to businesses, and only with proof of a business license.
However, that was not mentioned in the email I received with the payment information.

Has anyone ever shopped there, perhaps even as a private individual?
What were the experiences like?

Thank you and best regards.

Kiko.

I shopped there just like any other regular customer. The service is kind of... well, more or less random.
You could have also had my milling machine .

Hello, fellow diesel enthusiasts,

There's some news:

The engine is running again. The repair was completed yesterday. I will upload the photos and videos this afternoon and write a short report.

I just wanted to briefly vent my frustration with Dieselkontor. (Regarding the daily soup: Thank you for your offer, I would have liked to take it and probably had fewer problems. It's always easier to see things clearly after the fact.)

Okay, so I ordered the milling cutter online on May 22nd. On May 23rd, I received a payment request asking me to transfer the amount. The shipping cost for Spain was listed as €19.90, although a lower amount was indicated in the online shop.
In total, I transferred approximately 150 euros.
I then politely inquired whether they could ship the tool if I sent them the proof of payment, even though the money hadn't arrived yet. In response, I was told that UPS had already left, but that it might be possible to ship it on Tuesday (May 24th).
So, I was happy and waited. In the meantime, I asked for a tracking number. No response until Monday, May 29th.
Okay, Wednesday was a public holiday in Germany (Ascension Day), and Dieselkontor will be closed on Friday.
On Monday, I received a message saying that the item was in transit and that a colleague would send me the tracking number later.
On Tuesday, I inquired about that number again and received a response stating "yes, it's on its way."
On Thursday, June 1st, I finally received a tracking number after I had to ask more insistently.
With that number, I was able to determine that the milling cutter wasn't actually shipped until Monday, May 29th.

Yesterday, the item finally arrived, and it was delivered by regular mail. The shipping cost was actually €6.20 (international letter, uninsured). Additionally, the tool was sent to my billing address instead of the delivery address I provided. Fortunately, the mail carrier knows me and came back to my house in the afternoon. Otherwise, I would have only been able to pick up the package at the post office on Saturday.

In addition, the milling cutter was tampered with. The manufacturer's logo was sanded off, and the emblem on the plastic box was also removed in a rather unprofessional manner.

I have a certain suspicion, but I will keep my theory to myself. If possible, I will no longer shop at Dieselkontor.

Regarding the router bit, I can only say that it works excellently and the quality is very good. It took about 30 minutes to make the surface flat.

More details on that will follow later.

Greetings from the Costa del Sol (26°C at 9:28 AM).

Kiko.

I'm sorry if my link led you to order something; it was only meant to be an example of what something like that looks like.

The manufacturer's logo was likely removed to prevent people from discovering where and at what prices the product is being purchased, which is a common practice.

During my time at Konvekta, the original equipment (OE) numbers were manually removed from Bosch and Spal fans and blowers, and replaced with in-house numbers.

But it's great that it worked out, the engine was saved, and despite everything, the costs remained within a reasonable range.