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Author Topic: kaputtwagen 1982 rabbit AAZ swap/build  (Read 79575 times)

Reply #15August 22, 2009, 10:48:47 am

stewardc

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #15 on: August 22, 2009, 10:48:47 am »
I'm greatly envious of your PD150 intake. I presently have a 1.6 intake on my AAZ and am looking for a good/cheap intake to replace it with.
Great build....you'll love the AAZ in the bunny-I do.

Reply #16August 28, 2009, 11:03:37 am

GEE-BEE

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    1981 with South African front end ,42 k original
Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #16 on: August 28, 2009, 11:03:37 am »
Nice EGR block off plate on ebay 22.50

search : VW EGR

ITEM : 370081915897

Iam using McNally gauges on mine , Ouch 780.00 for a set of three

OIL TEMP/ PSI
WATER  / VOLT
EGT/PSI BOOST
1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #17September 02, 2009, 06:52:46 pm

jack's lack

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kaputtwagen 1982 rabbit AAZ swap/build
« Reply #17 on: September 02, 2009, 06:52:46 pm »

So this showed up in the mail. It really does not get much better than opening a box and finding this. ;D


I ordered seats and inner springs, so I am playing with a full deck now.



I finished my P&P job, got the ports matched and got all the casting marks out. like it has been said before this isn't hard, just very tedious and time consuming. I caught a dremmel on fire in the process, so now I am on number 3. Some day I will have to invest in a nice big air compressor.
The head has the usual cracks between the valves and some around a couple of the prechambers, but nothing looks too bad.


I got the injectors, also rebuilt by Giles, and new bosch fast glow plugs in. And yes I used new heat shields, I don't know why I had 2 of the old ones in the photo above. Reassembly was a lot easier than I anticipated, getting the keepers back in was a little tricky, but no where near the headache I was prepared for. I forgot to order a camshaft oil seal, so the cam will have to wait until I order new rings, because there is no way I am paying shipping for such a tiny part.


Some of you wanted to see pictures of how the PD intake fit so here you go. You can see in the last picture the post that had to be trimmed to clear the compressor housing. These photo are taken with gaskets in place, so it should be identical to final assembly.


Finally I broke the bottom end down. Two sets of bearings were chewed up, which explains all the metal I found in the oil pan. This scored the crank a bit too, but no worries since I am using a 1Z crank. What causes this to happen?

Next up I am going to take measurements of the bores and the pistons. Fingers crossed it will just be a hot-bath, a hone, and a re-ring.
« Last Edit: July 23, 2017, 01:52:09 pm by jack's lack »
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #18September 02, 2009, 07:21:54 pm

GIDDY_UP_GO

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #18 on: September 02, 2009, 07:21:54 pm »
Love the rims!

Your wife must be pretty cool to let you put all those dirty ole parts all over the house and on the counter top!  ;D My wife would have a fit!

When you put the engine back into the car, do you leave the turbo and manifolds installed on the head? Do you place the bottom end in 1st then place the head on with all the intake exhaust and turbo already installed onto the head? (Just curious, I have never taken an engine out or installed one, and probably never will)

Thanks for taking the time to show and explain your build! I am envious of your skillz!
86 MK2 Golf Diesel

Reply #19September 02, 2009, 08:26:18 pm

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #19 on: September 02, 2009, 08:26:18 pm »
Thanks, and I'm not married, not sure if I would be for long if I was living with a woman and working on this project in the house ;).  I don't think anyone's wife is that cool. I really need a garage. Plus the parts are pretty clean now, that's why the sink is an absolute mess ;D

As for the install, I'm still a bit from that point, but the plan is to completely assemble the engine, jack the car way up and slide the engine under and into place, then lower the car and bolt up the mounts. Once it's in I'll bolt up the down pipe intercooler piping wiring, hoses and the like. I think this will work, but like anything on an old VW I have come not to expect it to go smoothly on the first try.

Skillz huh? The only reason I am confident in doing this is because of the wealth of knowledge available on this forum. Between the bentley manual and the search function here I have answered almost all of my questions. When I do have a question the knowledgeable people on this forum have been quick to weigh in, without the pretension and judgment you might find on another very popular forum where on every thread some jacka$$ posts an animated gif of someone ejaculating on the screen. Seriously thanks to everyone for your help and support. This has been a lot of fun.


I forgot to mention in my update that I got the manual steering rack, tie rods, tie rod ends, u-joint shaft and new boots all swapped in. I did the old eyeball alignment on the driveway, with a bit of negative camber. I took it out on the highway, and wow what a difference. I have never felt so in control, almost like the car is anticipating what I want it to do. I had to modify the bracket that holds the shift linkage to the steering rack a bit, I just had to drill a hole and move a bolt. Other than that it was way easier than re-installing the power steering rack. I am gonna sell all of the power steering parts, so if someone is looking to go the other way, shoot me a pm

I spent a few hours at the cash&cary the other day and I grabbed a 120A bosch alternator out of a MKIII passat , but I took it to the autozone and it's fried, so there goes $20. They did have an audi with black leather seats that were in great shape. I think I am gonna have to call and ask how much $. I think they would look really good, and if I see another set of plaid recaros in a MKI I may have a fit. My MKIII seats are just not to my liking. Oh the same audi also has a K26 bolted to it, maybe I should grab that too?
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #20September 03, 2009, 10:44:43 am

GEE-BEE

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #20 on: September 03, 2009, 10:44:43 am »
Looking Good !

Should of ceramic coated that exhaust manifold !

Iam ceramic coating from the DP back, it's a 2'5 Techtonic's

Gee-Bee
« Last Edit: September 03, 2009, 10:47:54 am by GEE-BEE »
1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #21September 03, 2009, 11:37:53 am

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #21 on: September 03, 2009, 11:37:53 am »

Should of ceramic coated that exhaust manifold !


I'm still seriously considering it, I will probably send it off to Swaintech with the pistons and the turbine housing as well, but I am running low on funds, this project is going to drag on longer than I expected, oh well.
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #22September 03, 2009, 03:33:34 pm

lord_verminaard

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #22 on: September 03, 2009, 03:33:34 pm »
Yeah, that's how these things go.  My project was originally going to be a hone, ring, and go, but almost a year later and we are just now in the finishing stages.  :P

Looking great so far!!!

Your plan for installing the engine sounds good.  I bet you will find that it actually will go as easy as you said it will.  :)

Brendan
81 Scirocco 'S -->Soon to be m-TDI
93 Corrado SLC VR6
'86 Golf N/A Diesel  -->Wife's car
1990 Audi CQ
05 New Beetle PD TDI


"I am a man, I can change... if I have to.... I guess....."

-Red Green

Reply #23September 08, 2009, 08:06:48 pm

jack's lack

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kaputtwagen 1982 rabbit AAZ swap/build
« Reply #23 on: September 08, 2009, 08:06:48 pm »
So I took the measurements and great news, all are well within tolerances and a lot were dead-on pistons are all within .001" I made a spreadsheet for the bore measurements. the worst number is .0025", and Bentley says .0039" is the limit. So we are good right? I'm gonna call around tomorrow and find a shop to hot tank and hone it, then I am gonna call swaintech and get these pistons off, and order a set of rings. Finally some good news on this thing. 8)



Also the 1Z crank pictured left has a disk bolted to it that the AAZ crank does not have. What is it? and can I remove it?
« Last Edit: July 21, 2017, 10:57:25 pm by jack's lack »
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #24September 08, 2009, 11:49:02 pm

Powered by Spearco

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #24 on: September 08, 2009, 11:49:02 pm »
That is the crank pulse trigger wheel that is used for the crank position sensor. Its a 1Z TDI right?
'87 Syncro Transporter Single Cab "Now TDI"
'78 Rabbit..Gas Weekend Racer
'81 Caddy..Diesel 1.6/1.9 TD hybrid 275HP 349TQ "Retired"
'90 MultiVan, 2.5 Suby Swap, Porsche Brakes
'76 Scirocco TD dragster project
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'98 Puch G320

Reply #25September 09, 2009, 12:34:23 am

Syncroincity

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #25 on: September 09, 2009, 12:34:23 am »
Looks good, Ryan... good to hear something in spec on that motor. Sounds like it spun a bearing, that's usually the cause of chewed bearings; the bearing shifts in it's saddle and blocks the oil hole, and it's all downhill from there. This is what I was talking about when I said it had Montclair, CA, origins; Quality German Auto... those guys have a spotty history with their motors. He does get them from Germany, but God knows where he digs them up.

I just bought the same intake for my setup. :D Should make setting up the AWIC simpler, and I may send it to Extrude Hone for internal polishing.
JC McCavitt
'86 Syncro GL Camper AAZ
'98 Jetta Wolfie
'04 Passat Variant GLS 4Mo 5MT

Reply #26September 09, 2009, 01:59:38 am

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #26 on: September 09, 2009, 01:59:38 am »
That is the crank pulse trigger wheel that is used for the crank position sensor. Its a 1Z TDI right?

yep 1Z TDI I just found the sensor in the Bentley and I asked over on the IDI forum, and just got the same answer. I think I'm going to just take it off

oh, I think it spun a few bearings and a couple of thrust washers, it was a bit of a mess, but the block didn't seem to take any damage. Speaking of which, where do you find the bearings for the connecting rods? I can find the main bearings and the thrust washers easily enough, but the con rod bearings seem to be a rarer bird.

Extrude hone would save you a lot of headache. It was a PITA trying to sand it by hand and with a flapwheel on a flexshaft, it worked though, and it was cheap, just time consuming.

also Jerry, does the offer still stand on the alternator, I have had one hell of a time trying to find a new one? Sorry to hear about your woes with those sweet rods you bought, that really stinks.

I feel like this thing is finally getting close, I can't wait to start reassembly
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #27September 09, 2009, 08:31:38 pm

Syncroincity

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #27 on: September 09, 2009, 08:31:38 pm »
Absolutely, PM or e-mail me with your address again, please.  Just a thought... two bad alt.s in a row, maybe you should find another tester?? ;)

I solved my little clearance issue with the vigorous application of grindage with the ol' Dremel. Eh, the first assembly is always just practice, right? ::) At least I found the broken ring! I'll post some pictures tonight, the clearance to the oil squirter tabs is miniscule, but it works...  I win. :D
« Last Edit: September 09, 2009, 08:36:20 pm by Syncroincity »
JC McCavitt
'86 Syncro GL Camper AAZ
'98 Jetta Wolfie
'04 Passat Variant GLS 4Mo 5MT

Reply #28October 02, 2009, 07:38:47 pm

jack's lack

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kaputtwagen 1982 rabbit AAZ swap/build
« Reply #28 on: October 02, 2009, 07:38:47 pm »
ok a few new things

IGot the block back from the machine shop. I had it hot tanked and honed. I took another set of measurements, it is still within spec, but a little closer to needing a larger bore. I think it is ok though, chime in if you disagree.

I went ahead and measured the ring gap too, it is pushing the limit on the bottom ring, but I don't know what I can do as these came in a set.

I painted the block with duplicolor engine enamel, color is new ford gray. I am pleased, it was easy enough, but it needs a week to cure!!!

Do you like my engine stand? I think it's great.

The exhaust finally showed up, however there is a problem with the turbo flange. Hopefully it will get sorted out quickly though, otherwise it looks great, and I went ahead and polished the tailpipe.


I have ordered a full set of bearings from Myke W. I am considering getting them low-friction coated when I finally get the damn turbo apart and so I can send a bundle of parts to the ceramic coater. I have been working on one bolt. I have sprayed it with PB Blaster at least a dozen times, I have hit it with the torch, and it will not budge. It is in such a place that I can only get to it with an open ended wrench. I can't even get the flare nut wrench on it, so it just slips off. I have no idea what to do, and I am about to give up on having the turbine housing coated.

I put a new seal in the waterpump and a new low-temp tstat. It is crazy all the little things you have to reassemble when you are doing a project like this. It has been way more work than I  thought, but I am still very excited.

Cheers
« Last Edit: July 21, 2017, 11:23:59 pm by jack's lack »
1982 Rabbit diesel L 4 door
AAZ, K14, Giles pump, PD150 intake, P&P'd head, ceramic coated pistons, 2.5" stainless down pipe & exhaust. FK coils

My Build Thread

Reply #29October 03, 2009, 12:24:08 am

Baron VonZeppelin

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #29 on: October 03, 2009, 12:24:08 am »
I've never had to try it- but have been told and have read- heat the part with the torch again- and put a candle against it. Repeat that a couple/few times.

The super heat lets the wax penetrate like nothing else.

Once it cools - give it the wrench.

Supposedly it works everytime.

If you can't get access the to thread end of the hole - it might not work. You'd have to grind away the outer portion of head of the bolt - leaving what was the head - as an axle - so to speak.

In other words, not just lopping off the entire bolt head.
Leave an "axle stub" to get vise grips onto. Then the wax can go down into and around the threads.

Or just lop off two sides of the head - leaving a box shape that a wrench can fit. And still give the wax some access/clearance to the thread hole.

Maybe post a picture of said bolt and more ideas will flow.

 

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