Jetta Clutch - crank free play

[DrT]

Hi all,
I just wanted to share my experience in case someone else is suffering the same. I have a 2007 Jetta 2.0 FSI. This is the red "I" turbo (not supercharged) model - something of a rarity as I understand it.
Recently I noticed the clutch biting point changed occasionally. Sometimes it would feel normal, others it would bite about half way down from normal. I then noticed it did it almost guaranteed after going round a roundabout or long right hand bend at a decent speed. It went in for investigation to a small local garage and the clutch master cylinder was changed. That made no difference. It's now in the local VW franchise with the gearbox and the bottom of the engine off. It turns out the problem is end float (free play) on the crank, allowing it to move and press on the clutch mechanism, hence the problem on right hand bends. To make matters worse, the dealer tells me on that model of engine the crank is not removable - it requires a complete new engine. To get to this stage of diagnosis it currently stands at £1010 including VAT. The car is covered by a Warranty Group warranty but I'm guessing they are going to try and wriggle out of it under the "wear and tear" clause. The VW dealer has approached VW to ask about a replacement engine out of goodwill, but VW have said a) it's over five years old, and b) the last service was not at a VW franchised dealer.
Oh, I almost forgot - the cost of the new engine - around £7000

[Crasher]

Yes I have heard of the BWA engine suffering from crank thrust face/washer failure, quite a few cases have been brought to my attention, apparently one lead to a court case against a VAG tuner. I think the thrust face is insufficient for the pedal load applied by the clutch pressure plate. They reduced the thrust area by 50% on the EA113 series engines over the EA827 which I have only seen suffer thrust failure twice in 30 years.

[DrT]

Latest on this - The Warranty Group want me to pay £1600 to have the engine removed and sent to an engine specialist for further diagnosis. They won't consider a claim until they can determine the cause of the free play. A DEKRA technician has inspected the car and measured 8 (eight) mm of float on the crank. The manufacturer tolerances are 0.017 to 0.037mm.
I've been without my car now for almost three weeks while I try to get the dealer (The Car People), the warranty company (The Warranty Group) and the finance company (Black Horse) to take responsibility.
If there are any experts out there know the thickness of the thrust washers I'd be happy to know. I'm hoping the 8mm float is about the same as the thickness of the thrust washer, in which case it looks like that will be the culprit and I might get the claim settled.

[Crasher]

Each thrust washer either side of the crank is 2.475 mm so something is seriously damaged, namely the crank and the block and they will not be repairable. A new block is £1500 and a new crank £470 so the most sensible solution would be a VW exchange base engine at £3300 because a short engine (block/pistons/crank/sump) is not available from VW.

[DrT]

Here's another update. The photo shows the wear if you look closely, and you can see the thrust washer isn't seated properly. I couldn't see it in the dim light but the mechanic told me the block is worn as well as the crank. Still battling it out with warranty company though...crank_close.jpg

[DrT]

Hi Crasher. You seem to be very knowledgeable on here. Have a look at the attached photo please. I spotted this when I went to look at the damage and then I recalled that a few months back the dealer (the one where it is now) sent me a letter telling me my cam belt was due for changing. I'm not mistaken am I? That is the timing *chain* hanging down isn't it? It's obviously not connected to the crank damage but I thought it quite amusing that the VW dealer doesn't know what engine is in my car, and that they send out random letters hoping some old dear will go with the flow. I wonder what would have happened if I'd took it in and said, "go on then, replace the cam belt". I wonder if they would have admitted their mistake.chain.jpg

[Crasher]

That is the oil pump chain.