G60ING
Top Post Dawg
- Joined
- Aug 5, 2001
- Location
- MD
- TDI
- No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Fears from a previous generation of crank snout design have cause me to do this, well that and having had an issue that caused me to replace the crank cog.
I just picked up a box of 3/16" dowel pins from Granger and will take pictures outlining how I'm pinning the timing belt cog to the crank shaft. Over all its fairly simple. Drill the crank cog on a drill press or mill and then put it on the crank and use it as a guide for drilling the holes in the crank.
I plan on putting two in for 7,200 lb shear strength.
Thats what my friend and I agreed for the best fit.
I used the old bolt to hold the cog square & snug on the crank:
A word of warning, make certain you have the holes deep enough. I'd suggest that you do this with the cog off the crank. Put the pins in the crank, and then measure how far out they stand. If you install the pins with the drill bolt in place you will have a challenge to get the drill bolt out...I learned the hard way buy I overcame the lesson.
Nice snug fit with the use of the reamer.
Yes the timing belt does need to come out to do this.
The dowel pins that I used were 3/16" x 1.5"
I have a lot of spare pins I don't know if this is something the moderators would hate (i'll delete this if so) but I'll ship two pins out via first class mail for $5. This will save you the hassle of buying a bulk like I did.
Here is what I bought if you want to spend the extra money for a box of 50 for $14 Plus shipping if you can't pick them up: http://www.grainger.com/Grainger/Dowel-Pin-2MB66?Pid=search
Here is the reamer:
http://www.fastenal.com/web/products/detail.ex?sku=360068-131588&ucst=t
Here is the final pass drill bit (before the reamer):
http://www.fastenal.com/web/products/detail.ex?sku=53012&ucst=t
You will also need a new bolt, I used the old bolt to hold the sprocket in place while I drilled the crank. I had to grind the sides of the old bolt (shown in the pictures)
I bought the pins, reamer and drill bit because its about once a year that I have my hands on a strange motor that should be pinned during a rebuild or whatnot.
Here is a picture of the dealership tool for torque procedure on the crank sprocket:
The VW crank holder can also be used to hold the cam gear when doing the TDI timing belt. Its $65 from Worldimpex: http://www.worldimpex.com/parts/oem-counter-support_238827.html
I just picked up a box of 3/16" dowel pins from Granger and will take pictures outlining how I'm pinning the timing belt cog to the crank shaft. Over all its fairly simple. Drill the crank cog on a drill press or mill and then put it on the crank and use it as a guide for drilling the holes in the crank.
I plan on putting two in for 7,200 lb shear strength.
The AHU crank has the flat also.
If I were doing it I would use an 11/64" drill the way you plan then go through both the pulley and crank with a 3/16" reamer.
Thats what my friend and I agreed for the best fit.
I used the old bolt to hold the cog square & snug on the crank:
A word of warning, make certain you have the holes deep enough. I'd suggest that you do this with the cog off the crank. Put the pins in the crank, and then measure how far out they stand. If you install the pins with the drill bolt in place you will have a challenge to get the drill bolt out...I learned the hard way buy I overcame the lesson.
Nice snug fit with the use of the reamer.
I would recommend drilling the sprocket out on a drill press or mill. Once the sprocket holes are made you can use a regular hand drill to drill the holes in the crank.G60ing, is this something that can be done in the car? If so, are you just using a right angle drill to drill and ream the crank?
Is this something that requires a TB change at the same time?
How long were the dowels you purchased?
Yes the timing belt does need to come out to do this.
The dowel pins that I used were 3/16" x 1.5"
I have a lot of spare pins I don't know if this is something the moderators would hate (i'll delete this if so) but I'll ship two pins out via first class mail for $5. This will save you the hassle of buying a bulk like I did.
Here is what I bought if you want to spend the extra money for a box of 50 for $14 Plus shipping if you can't pick them up: http://www.grainger.com/Grainger/Dowel-Pin-2MB66?Pid=search
Here is the reamer:
http://www.fastenal.com/web/products/detail.ex?sku=360068-131588&ucst=t
Here is the final pass drill bit (before the reamer):
http://www.fastenal.com/web/products/detail.ex?sku=53012&ucst=t
You will also need a new bolt, I used the old bolt to hold the sprocket in place while I drilled the crank. I had to grind the sides of the old bolt (shown in the pictures)
I bought the pins, reamer and drill bit because its about once a year that I have my hands on a strange motor that should be pinned during a rebuild or whatnot.
Here is a picture of the dealership tool for torque procedure on the crank sprocket:
The VW crank holder can also be used to hold the cam gear when doing the TDI timing belt. Its $65 from Worldimpex: http://www.worldimpex.com/parts/oem-counter-support_238827.html
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