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Author Topic: kaputtwagen 1982 rabbit AAZ swap/build  (Read 79576 times)

Reply #30October 03, 2009, 11:53:57 am

GEE-BEE

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    1981 with South African front end ,42 k original
rabbit AAZ swap/build
« Reply #30 on: October 03, 2009, 11:53:57 am »
My intake assy I did in Silver powder coat and I picked up two used turbo and sent both housings and the exhaust manifold and the two heat sheilds out for ceramic coating, They came out great it was around 250.00 for everything from a local shop here.

Iam going to send both turbo's to GPOPSHOP for OHC and I will probly sell the extra one since I already have a spare.

What was the problem from Techtonic's on the flange ?

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 #31October 05, 2009, 10:28:02 am

lord_verminaard

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #31 on: October 05, 2009, 10:28:02 am »
You will like the Swaintech coating.  After I got the pistons back all I could do was ooh and ah at them for a while.  :)

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 #32October 05, 2009, 06:52:48 pm

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #32 on: October 05, 2009, 06:52:48 pm »
I have a quick question/concern. I have read a couple of places about buying two sets of bearings and not using the number 3. What's the deal with this? the number 3 was chewed to sh*t and the thrust bearings were pretty chewed up too. I don't want this to happen again, what can I do to make this thing bullet proof. I figured low friction coating would give me some insurance, but I'm still nervous.
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 #33October 05, 2009, 07:35:27 pm

theman53

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #33 on: October 05, 2009, 07:35:27 pm »
I have a quick question/concern. I have read a couple of places about buying two sets of bearings and not using the number 3. What's the deal with this? the number 3 was chewed to sh*t and the thrust bearings were pretty chewed up too. I don't want this to happen again, what can I do to make this thing bullet proof. I figured low friction coating would give me some insurance, but I'm still nervous.

Contact Myke W. He is a mod here and has the correct set of mains for the engine. I believe the problem is when the main bearing has the intergrated thrust washer. It ends up eating the crank shaft, but the stock design with the separate washers do not. Also, the #4 I believe ,check the faq, is the one if you use the extra or myke w's set has a 360 degree slot. This is for better oiling in the head and I think #3 rod if I am not mistaken.

Reply #34October 05, 2009, 08:19:14 pm

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #34 on: October 05, 2009, 08:19:14 pm »
Well I ordered my bearing set from Myke W, so I should be good then huh?  :)
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 #35October 06, 2009, 11:31:58 am

lord_verminaard

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #35 on: October 06, 2009, 11:31:58 am »
Yep, you should be good to go, though you may have to order new thrust washers if yours are chewed up.  I got lucky with mine, I re-used them and the endplay was still bang-on.  :) 

Myke's bearings have the proper 360 bearing, I also cannot remember if it's #3 or #4 but I know I used it.

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 #36October 06, 2009, 08:23:34 pm

Syncroincity

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #36 on: October 06, 2009, 08:23:34 pm »
#4 gets the 360 oil channel... I found it in the archives after spending an hour trying to figure out why I had an extra channeled bearing. I thought Swain had lost one. :D
JC McCavitt
'86 Syncro GL Camper AAZ
'98 Jetta Wolfie
'04 Passat Variant GLS 4Mo 5MT

Reply #37December 03, 2009, 01:43:39 am

NintendoKD

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #37 on: December 03, 2009, 01:43:39 am »
awesome build, an absolute inspiration.  thanks.
dnahtasinoivilboeraweb
you know, decarbonated beer is a better coolant than the stuff you buy at the auto store, and is better for you...... really
"If the boost were to rise then the throttle would remain in the wide-open throttle position, which might be fun, but probably not for long"Libbypapa

Reply #38December 08, 2009, 02:20:30 pm

jack's lack

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kaputtwagen 1982 rabbit AAZ swap/build
« Reply #38 on: December 08, 2009, 02:20:30 pm »
Okay, sorry it has been awhile. I'm a grad student and this fall quarter was nuts, but only 4 classes (20 hours) stand between me and my masters.
I'm on break, so back to work on this lump

I got the pistons and the bearings coated by Swaintech. Piston has goldcoat on the crown and pc9 on the skirt. Sorry I did not take a pick of the bearings, but it is just a low friction coating looks a lot like the piston skirt


I got ARP mainstuds I used the number on here for the 1.6 and they fit. 204-5402 is the number if anyone needs it


I used the Craftsman universal spring compressor to get these guys in. It was really pretty easy. Rings gaps are spaced 120º apart as per the Bentley spec.
I really love the color combo of the gold coat and the gray block paint.


Next I dropped in the bearings and the 1Z crank and bolted it up. I torqued the mains to the bentley spec first and then brought them up to the 60 ft.lbs ARP specs
I found out that the ARP connecting rod bolts I ordered (104-6002) do not fit. They apparently only fit the 1.6 engines. After much correspondence with the ARP tech I was still unable to get a good number for the AAZ >:(

The problem is that the AAZ bolt threads into the connecting rod itself. It DOES NOT have a separate nut and stud.

What did work surprisingly is ALH connecting rod bolts. the spec is M8x1.0x45 (really more like 43mm) the ALH is only threaded for the last 13mm or so and the bolts I took out were threaded for 32mm, also the dowel on the ALH bolt is much closer to the threads. However they fit and torqued up nicely (# on the bolt is 028 105 425C).


Wow it feels good to rotate a freshly assembled engine doesn't it? I can't wait to hear it roar to life for the first time.
so next step is piston deck protrusion. Many people have shared their rigs for getting this number so I will share mine.

It is my dial gauge for IP timing with a nut as a spacer threaded into some aluminum channel with some 1/2" washers epoxied to them. Nice huh?
Anyway I zeroed it on the deck and then I spun it around a few times and took measurements on all the pistons mostly I got .030" but a couple times I got .032" either way that is well within the 1 notch range. It had a 3 notch on it before, but it was pretty shoddy looking anyway. most of the black paint or coating or whatever had peeled off needless to say it did not inspire confidence. So I ordered a 1 notch Victor Reinz from Autohaus AZ and priority shipped it Hopefully it will get here Thursday or Friday. if nothing goes awry I might be putting it in this weekend.

A few post's ago I mentioned that the flange on my downpipe from TT was wrong. I had considered sending it back to them, but the more I thought about it, it just seemed easier to fix it myself. All I had to do was drill 2 more holes. I think it will work for a K03 and a K14 now  ;)


here it is bolted up. I don't think it looks too bad


I started sorting things out and figuring out which bolt goes where while I wait for the headgasket (zylinderkopfdichtung I wish I got to use that word more often). I also soaked the wastegate adjustment screw in PB for awhile and got it free. I went ahead and screwed it all the way in.;D I am going to see how that works and if I don't like it I will spend a few hundred on a boost controller. So here it is as it sits


I hope to have more by the end of the week.
« Last Edit: July 21, 2017, 08:44:06 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 #39December 08, 2009, 02:56:20 pm

NintendoKD

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #39 on: December 08, 2009, 02:56:20 pm »
I'll take those arp crb off your hands I will need them for my build, nice work, looks excellent so far.  I plan on sending my stuff off to a coater as well, how are their prices?  anyone I should talk to over there?

thanks,

Kevin
dnahtasinoivilboeraweb
you know, decarbonated beer is a better coolant than the stuff you buy at the auto store, and is better for you...... really
"If the boost were to rise then the throttle would remain in the wide-open throttle position, which might be fun, but probably not for long"Libbypapa

Reply #40December 09, 2009, 11:08:41 am

GEE-BEE

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #40 on: December 09, 2009, 11:08:41 am »
I hope to have the AAZ silicone engine hoses done in a few weeks, so I will keep you advises

Like the block color..

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 #41December 10, 2009, 09:54:46 am

lord_verminaard

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #41 on: December 10, 2009, 09:54:46 am »
Loving it.  Looks great.

Don't spend a couple hundred on a boost controller.  The boostvalve will work just as good:
http://www.boostvalve.com/volkswagen_2.html

The A3-BV is for wastegated diesel's. Only $49.00!

I'll be using that one, if the need arises.  Hitting 15psi right now with the wastegate blocked, but that's with a cracked intercooler.   ::)

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 #42December 10, 2009, 10:39:41 am

jack's lack

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #42 on: December 10, 2009, 10:39:41 am »

Don't spend a couple hundred on a boost controller.  The boostvalve will work just as good:
http://www.boostvalve.com/volkswagen_2.html

The A3-BV is for wastegated diesel's. Only $49.00!

Brendan

Thanks Brendan.
When I saw $50 I was sure you were linking me to a bleeder valve, and I was worried I was going to have to be all snobbish as to why that is not good enough.

I'm putting together my intake piping now. I'm going with aluminum straight sections and silicone connectors and elbows.
I got a bar and plate design FMIC that will fit in front of my radiator on ebay for $60 :o The similar one that siliconehoses.com sells was $170. It is good the intercooler was cheap because the piping is outrageously expensive. my first scheme was $800. I have simplified it and made sure I have easy access to my valve cover now and I am at about $500. I could take another $150 off of that if I just use the stock intake hose.

Intercooler should get here tomorrow, so I will get some pictures up, and the headgasket should come today. So I will be doing some serious assembly later on.
« Last Edit: December 10, 2009, 10:41:52 am 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 #43December 10, 2009, 11:20:48 am

GEE-BEE

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Re: kaputtwagen 1982 rabbit AAZ swap/build
« Reply #43 on: December 10, 2009, 11:20:48 am »
Make a build list complete for the MK1 Intercooler, If you need any gaskets made or a silicone elbow ?
Shoot me a email
[email protected]

I will send you a pdf catalog

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 #44December 11, 2009, 08:01:28 pm

jack's lack

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kaputtwagen 1982 rabbit AAZ swap/build
« Reply #44 on: December 11, 2009, 08:01:28 pm »

so here is the intercooler. I'm psyched, not bad for $60. I'm going to try and fit it and get it mounted tomorrow.

Too bad there is still no sign of my headgasket. I hate waiting on stuff to get here, but I love opening boxes full of parts.
« Last Edit: July 21, 2017, 07:43:21 am 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