AEL Zahnriemen gerissen. Nockenwelle viermal gebrochen! | Posts 48+

Hi,
According to Etzold, the new screw for KW requires a torque of 160 Nm plus a rotation of 180 degrees. The 180 degrees can be achieved in several steps.

Hello,

Thanks for the information. I've now moved the two ZK units to the warm office to...
Engine components, including the exhaust manifold, should be significantly above 0 degrees Celsius.
to exchange.

http://people.freenet.de/kmrlange/neuer_ZK22.jpg

Dann kommen die WaPu und das Thermostat an die Reihe. If it's...
I'll get back to you about the specifics. I'm just wondering why the Visco fan isn't working.
How to get rid of it remains a mystery to me.

That's why the third screw of the WaPu is quite a fiddly thing to deal with.

Best regards, KAi.
PS: You should treat yourself to a new ZK every spring.

http://people.freenet.de/kmrlange/neuer_ZK1.jpg

Hello,

I've just recently registered for this forum. But what I saw regarding the tensioner for the AEL motor is what motivated me to sign up.
I've seen several engines fail due to the 'good' tensioner pulley coming from Canada. This problem has been known for several years in VW and Audi vehicles. It surprises me that defective tensioner pulleys are still appearing.
You should definitely contact your Audi dealer regarding a warranty claim for the tensioner pulley. If the pulley is less than two years old, a new engine should be installed.
If the camshaft has broken multiple times, the piston protrusion measurements should definitely be checked to rule out the possibility that the connecting rods and bearings are stressed.

Best regards,

volkswagen polo

Hello,

I wouldn't trust that Canada-made tensioner for more than a dime. The new one, however, has...
other letters after the part number, but the construction and material thickness are the same.
identisch. Cheap.

The piston clearance is fine, as mentioned before. I'm hoping the crankshaft is undamaged. The tensioner pulley is just over three years old. You can read the polite letter requesting understanding from the excellent customer service a few posts above...

Despite that, the question arises whether one couldn't incorporate something worthwhile there? In a way, to turn something into gold. As the saying goes.

First, a fixed tensioner, and second, a water pump with a long slot for tensioning.
There was also a water pump like that for the five-cylinder engine. How is the tensioner for the timing chain adjusted on early versions of the AAT engine?
I would probably replace all three tensioners every 30,000 kilometers now, but something that breaks after 57,000 kilometers is statistically likely to fail after 27,000 kilometers as well.



Best regards, Kai Lange

Hello, don't worry too much, the tensioner pulleys have actually been changed (different material). To my knowledge, there hasn't been any engine damage yet due to the new tensioner pulleys.

Wow.

How can one distinguish between good and bad tensioners? If my new one has been in storage for three years, could it possibly be a 'Rumpelstilzchen' (a problematic, unreliable item)? I'm not getting any answers from AUDI that shed light on the situation, because if they did, they would have to admit that they are selling a product with a design flaw.

Best regards, Kai.

You can identify the tensioner pulley by the changed letter following the part number, which is also printed on the tensioner pulley itself.

In AAT engines up to 94, the timing belt is tensioned using an eccentric but fixed tensioner pulley. The water pump is fixedly mounted. This was likely the design used in older gasoline engines, similar to how it functions in smaller four-cylinder engines like the Opel 1.3L or the VW 801 series, where the water pump serves a similar purpose.
From my perspective, the disadvantage is that the large O-ring which seals the pump to the engine block tends to leak after a while when it's adjusted, and then the pump has to be removed. According to Volkswagen, the pump is not supposed to be replaced, although everyone in this forum seems to have a different opinion.

hm,

So, the AAT tensioner is definitely a possible alternative. I'll keep that in mind.

Now, the question arises: how do we (the workshops...) actually know that...?
Is the tensioner with the new part number better than the old one? I mean, is there a report about it from the manufacturer, even if it's just an internal one?

How do you (the professional mechanics) know that? There must have been some kind of announcement or information released.

Best regards, KAi.

Well, if you only ever install the new 'version' and fewer and fewer complaints are coming into the workshop, you can almost assume that the quality assurance department has done its job, don't you think?

by the way
You will never be able to completely eliminate a risk, as long as this endless thread continues... Please make sure to properly install and securely connect everything, and get your new KW (keyword) spinning.

As I mentioned before, I can only tell you that, in my experience, an engine failure in conjunction with a modified tensioner has not yet occurred.

Perhaps the water pump from the 5-cylinder T4 (aab?) would also fit, and you could adjust it using elongated holes.

OK.

I'm already quiet. I'm convinced. I'll get back to you when there's something of general interest or of interest to me (if there are any problems).

Best regards, KAi.

Hello,

If I may chime in here?

The tension spring 074 109 243J was replaced with a new one, number 074 109 243R, in December 1998.

@kmrlange
Based on what I can see in your photos, it appears that your broken tensioner is a 074 109 243R.
Are the new tension rollers still faulty?
What is the model number of your newly purchased tensioner?
Is the manufacturing date or serial numbers indicated on the tensioning roller?

@volkspolo and mersente
Have you seen any other suppliers of tension rollers besides the ones from Canada that supply Audi (AEL engine)?
I replaced the timing belt on a Golf 1.8L RP engine about 5 months ago.
The new tensioner, which I had personally obtained from VW, didn't have "Canada" printed on it and looked a bit more reliable.

Best regards,

Hello Goldhuhn,

The faulty tensioner was installed on my car in 2000. So, it must be the version from 1998.
The new one has an 'F' after the part number: 074 109 243F, so it's at least a third variant. It seems that nobody really knows when which tensioner was used, and for what reasons, and with what modifications.

My guess is that the 'Black Peter' was the 'R' version. The first product was expensive but good, the second was cheap but bad, and the third has been improved, let's see...

Best regards, KAi.

I just bought a new tensioner pulley for my 2000 AMF... thankfully, it looks a bit more robust... but apparently, according to VW, it's supposed to be replaced every 60,000 miles anyway.

But let's get to the point:
I'm just mentioning the German Product Liability Act (ProdHaftG). It stipulates a €500 deductible for you, but the manufacturer of the tensioner pulley has to cover the rest (regardless of fault!), provided you can prove the causal link (which, in this case, might actually be possible).
You can at least threaten them with that (with the manufacturer of the tensioning rollers, assuming they have a German branch...). In your situation, I would also recommend getting legal protection insurance so that you can go to court if necessary.
The statute of limitations of 3 years from the knowledge of the defect (§ 12 of the Product Liability Act) is not an issue in this case.
By the way, according to § 4 of the German Product Liability Act, the distributor is also considered the manufacturer, which means that certain pressure could potentially be exerted on Volkswagen.

Regards,

Olaf.

Hello again,

Now, the big moment has arrived. The murderer's vibration-damping crankshaft bolt.
It is actually still intact despite 200nm + 270 degrees .
The injectors are new or refurbished, and there are 6.5 liters of coolant with the good stuff.
Pale pink G12+ coolant has leaked into the cooling system.

I'm now taking a creative break, including childcare duties. And then it depends.
Please keep your fingers crossed for me that the five cylinders will turn out to be really beautiful later.
schwarzes Wölkchen raushusten und die Maschiene wieder nagelt. I'll get back to you.

Best regards, KAi.