1.9 PD ASC Replacement

Hello everyone,
Unfortunately, my Golf 4 (1.9 TDI, ASZ engine with 131 hp) has a broken crankshaft. While driving, it was making a rattling noise and misfiring... I initially thought it might be the dual-mass flywheel (DMF).
After removing the gearbox, you can turn the undamaged dual-mass flywheel. You can also turn the output shaft of the engine. However, nothing happens on the opposite side - the belt drive side. I suspect that the crankshaft is broken.

"Question: Can I install any other engine (like from a Seat Leon or an older Audi A3 8L) into a Golf? Does the engine code (MKB) need to be the same, but will all the mounting points and connections fit? Has anyone had experience with this?"
Thank you very much!

The Golf IV and the Audi A3 8L share the same platform.

You should expect that at least the attachments and electrical components/wiring will be different. The engine code (MKB) only refers to the main engine. However, that one should fit.
hg
Herbert.

Hello,

ich habe einen ASZ aus einem baugleichen Golf 4 gefunden. So far, so good.
Okay, here's the "Gretchen question": Does anyone in this forum have any experience or know if a clutch master cylinder (ZMS) that appears to be okay can actually cause the crankshaft (KW) to break?
Has anyone ever experienced something like this before? Right now, I'm still having trouble accepting that the dual-mass flywheel (DMF) is supposedly to blame.

Hi,

"Sometimes it's necessary to remove the oil pan. Occasionally, the main bearing screws can shear off, which is why nowadays almost exclusively M10x80 screws with a strength class of 12.9 are used. In the past, M10x65 or M10x80 screws with a strength class of 10.9 were also sometimes used. This kind of failure is particularly critical in cases of extreme (chip) tuning or when using starting fluids like brake cleaner or starter fluid."

Hello everyone,

I don't want to withhold the solution from you: The "new" ASZ fit perfectly. Of course, it was exactly the same design, even from the same model. So, the car is running again!
"The clutch, ZR (presumably referring to a specific component), and everything else can be replaced with new parts when the engine is completely disassembled."

Now, here's the interesting part:
"Damage observed in the old engine: Fracture of the crankshaft at the pin location of the second cylinder, on the left-hand side (facing forward). Not only is the seemingly welded-on pin broken off, but a portion of the shaft itself has also fractured. It appears very unusual. The fracture surface looks as if it was torn away and extends for approximately 5 cm."
Schwer zu beschreiben. Habe leider verplant ein Bild zu machen. Sorry.
That also explained why the engine was still running. The broken area was still being held together by the interference fit of the crankshaft. At least partially. Now there's significant axial play. I don't know if that's a result of the damage, or if the damage is caused by the play.
I'm also unable to determine if this is caused by the faulty dual-mass flywheel (DMF). Could the DMF exert enough force and pressure to cause axial play in the crankshaft, leading to it being literally torn apart? However, I'm ruling out the bearings and their screws as the cause. My friend, a mechanic who has been working since 1976, says he hasn't seen anything like this either.