TDI - AFN-Motor, Startschwierigkeiten, weißer Rauch, Ruckeln | Posts 32+

@ 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.

Hello Ruedi,

You don't need to apologize at all. Quite the opposite. I'm very grateful that I found the part so quickly. Without your information, I probably would have been searching for it endlessly, because it's not necessarily easy to find.

Here's a used copy available on eBay:

Milling tool, crankshaft, face milling cutter, VW-Audi, crankshaft / 252937040070.

The milling cutter works perfectly, and the quality is excellent.
I don't get the impression that he has worn out in any way.

If the engine is working properly again now, I will soon forget all the trouble I've had.

Thank you again to everyone for your participation.
Photos and a report will be available later tonight.

Regards,

Kiko.

Here are finally the pictures I promised. I didn't have time yesterday.

Images and results are shown below.

I then fabricated a new counter-hold from 6 mm thick flat steel. This allowed me to apply more force. However, I have to admit that I didn't quite manage the 90º angle. It felt like I was about to twist the crankshaft. Also, I didn't have enough space at the bottom. I think I managed to achieve about 70º.

I have read countless reports in this forum regarding the KW screw (I did have some time ). However, I have decided not to use Loctite or any other methods to secure the screw. I will simply observe it.
"It's lasted for 200 kilometers so far, haha..."

About 5,000 km ago, I drove for roughly two weeks with a faulty alternator one-way clutch. However, I initially noticed the broken tensioner pulley, so I replaced that first. After about 500 km, the tensioner pulley was broken again. Only then did I take a closer look at the one-way clutch. I then replaced it. I thought it couldn't be broken because I had already replaced it once before. However, I then checked my records and realized that it had been 7 years and tens of thousands of kilometers ago.

"So, I think that probably caused the KW pulley or the KW wheel to break. I'm not entirely sure if the large vibration damper on the KW might have also been affected. It seems like there's an imbalance somewhere. The tensioner pulley for the belt also vibrates a bit when idling. I can't remember if that was always the case. Does anyone know anything about this?"

I have another vibration damper lying around that is a bit newer. I could try testing with that one, or compare it to the one that's already installed.

As I said, we're observing the situation now. Either the faulty alternator clutch was actually the cause of the problem, or perhaps our TDI engines aren't failing due to the typical wear and tear of the cylinders, but rather due to the crankshaft stub.

I will keep you updated. Thank you again for your comments.

Regards,

Kiko.

Dear forum members,

I just wanted to quickly check in and provide an update.
The above-mentioned repair was carried out approximately 7,000 km ago, and everything is working perfectly.
This weekend, I changed the oil and checked the condition of the coil spring seat.
Torque was over 200 Nm. So, it seems everything is still tight (for now).

I haven't checked the valve timing, but I have checked the fuel injection timing, and it's within the acceptable range.

Let me know if there's any news.

Best regards,

Kiko.

Should the screw be replaced every time the timing belt is changed?

How can you prevent the formation of calluses?

Hello bindpe,

I'm sorry, I'm only able to reply to you today.

I drove my car for approximately 450,000 km without replacing the bolt. Although the bolt was always included in the timing belt repair kit, I decided to leave the old one in place. The combination of tightening torque and angle of rotation made me hesitant to change it.

I can't tell you for sure whether the shaft broke for that reason or not. All I know is that I had a faulty alternator clutch a while before, which I didn't fix right away because I thought the problem was somewhere else. The vibrations caused by that faulty clutch ended up costing me two belt tensioners (alternator belts) and a pulley.

The timing pulley may also have been damaged, or the screw may have come loose as a result. It's incredible how important it is for the alternator's freewheel mechanism to function correctly.

By the way, the milling repair was done approximately 12,500 km ago. The engine continues to run without any problems.

Regards,

Kiko.

Hello.
"How much does a milling cutter cost, and what's the repair process like? I can't quite picture it right now."

At Klann, a substantial three-digit amount; on eBay, around 100 euros.

Hello everyone,

I wanted to follow up again.
The repair using the milling cutter is now over 1 year old. Since then, I have driven a little over 30,000 km.
Everything is still running smoothly.

Best regards from Andalusia.

Kiko.