Need some 1.9 AAZ Rebuild Advice

[MoparEd]

What turbo did it come with?

I have a decent 1.9TD from a 95 golf that would fit right in there...

I`m also looking to rebuild my otehr 1.9TD.

Where to get the parts and what machine shop in the area has done many AAZ s before is what I`m looking for.
Anyone from teh site know?

Maybe we can get together and order bulk and get a discount on parts..

The car came with a Garrett T2

I emailed Giles at performancediesel.ca for some prices on rebuild parts, Im not sure of any machine shops in the area that has done aaz engines, Im hoping I can get away with honing of the cylinders myself and doing a ring and bearing job. Guess ill find out once I open the engine up and measure the bores.

Ed

[boxer246]

MoparEd you can get a good price on Bentley manual through Amazon.

[MoparEd]

So I managed to get the engine out of the car and apart last night. Im sadly disapointed in the condition of the tops of the pistons, It looks like I may be replacing them wonder if I can run tdi pistons and head with my aaz fuel pump?? The bearings however, looked great. Here are some progress pics:











All 4 pistons look the same

Ed

[burn_your_money]

wonder if I can run tdi pistons and head with my aaz fuel pump?

Maybe, I doubt it would run well or have very good power.

I have 3 standard size AAZ pistons you can have with rods. I think they have light valve kisses, nothing like yours. They are at the shop

[Vincent Waldon]

I'd be inclined to clean the carbon etc off the top of your pistons and see how bad they really are... these have been running fine many tens of thousands of kms:

[MoparEd]

I'd be inclined to clean the carbon etc off the top of your pistons and see how bad they really are... these have been running fine many tens of thousands of kms:

My god Vince,
What did you use to clean those pistons with? lol
Ive been googling like crazy to find what people are using to get carbon off their parts. I have a piston soaking in some simple green right now

Ed

[Vincent Waldon]

Very fine wire brush on a bench grinder... very gentle pressure.... stayed a long way away from the ring lands.

Breaks some rules I've read, but so does running pistons with holes in the coating.  

After I cleaned 'em up as per the picture I took a very fine file and radiused the edges of the divot caused by the valve... this removed the metal that had been "squished" up *and* got rid of any sharp edges that might cause hot spots.  So far so good.

'Course if you can get some better ones from Tyler why take a chance... but it *can* be done.

[MoparEd]

Thought id update my progress so far lol.

Ive been very busy with school and haven't actually been able to do much with my engine, but some progress has been made...  I took the disassembled engine to a machine shop to get some work done.  The block has been hot tanked and intermediate shaft bearings replaced, I have to get it bored because it was out of spec, so I purchased some prothe pistons (and a different set of rings). I also had the shop re-size my rods, polish the crank and decided to let them rebuild the head completely. all in all, with the price of the pistons, rings, bearings, gaskets, machine work, rebuilding of the head, I'm just over $1000.

I will still have to assemble the engine, and still need some parts like head bolts, main bolts, pressure plate bolts, rod bolts, water pump, clutched alt pulley, starter and clutch slave cyl and of course a bentley manual and crank bolt.  It should be a good runner when im done , but its hard to stay motivated since im married to the car now. I learned a good lesson tho, The next time I purchase a diesel vw, ill do a hell of alot more research. (I found this site after I purchased the car)

I try to not think about how much I have invested into it so far, especially when I see 2000 and newer diesel vws selling for less than what I have invested so far. and once I have the car running, I get to repair the other little issues with it (like windows going down by themselves, cruise control quitting after 5 minutes of use, etc...)

On a lighter note, The pistons came in today, and I will be delivering them to the machine shop on Monday, so the block can be bored to match cant wait to get this thing togather. Im deathly afraid to time the thing tho, It seems that I have a different injection pump than the ones I see on rebuild threads. I really have to invest in a bentley dvd or book.

Cost so far:

Car:     $1850
Pump:  $465
Tdi Crank Mod $500
Pump tested on stand and Installed $150
Machine Shop work , with Parts       $800 (so far)
Pistons  $235

Grand total: $4000 so far

Heart Breaking

Ed

[Vincent Waldon]

Im deathly afraid to time the thing tho, It seems that I have a different injection pump than the ones I see on rebuild threads.

No worries... post a few pictures when you get to that stage and we'll lend a hand.

[burn_your_money]

Good to see you making progress Ed.

You have nothing to fear when doing timing. Just make sure that you properly tighten all the bolts/nuts and that you turn the engine over by hand before you even so much as think about cranking it with the starter.

[gnavs]

how's progress coming?  Old lady put her foot down? 

[MoparEd]

how's progress coming?  Old lady put her foot down? 

Hahahaha, My fiance is more anxious to start building this engine than I am

Im still waiting for the machine shop to do their thing. It was suppose to be done last week, but when I called on Monday, Garry said it was going slowly but getting done. Im hoping the machine work will be done soon so I can get to building this thing. Im sick of staring at the car in the driveway and all the parts on the garage floor. I will be posting pics every step of the way so you guys can chime in and let me know how im doing

Ed

[VelocityConservation]

Ed,

Don't get discouraged.

I have a MKII and have more than that in my engine rebuild.  I am thrilled with the choice of sticking with the old simple iron.

I think all the electronics on the new ones would give me a bigger headache than the stuff I have left to do.

Besides if you are going to drive it for years to come, like I am, you will enjoy that you did it right now.

VelocityConservation

[Big Daddy Roth]

I'm going to be rebuilding the TD engine in my B3 as well.

What is this TDI Crank Mod? Do I need to use different rotating internals? What other swaps should I do while I'm at it?

[NintendoKD]

yo vince, since thie pic is up I wonder if you could possibly run pistons like that on a lathe?  I know it's a bit off topic, but could be a cheap alternative to running out and getting a new set, and help those doing rebuilds like this.

kevin