The Rebirth of Smokey Eddy - The 1.9 Saga

[Smokey Eddy]

*writes down* ...1 bag... army navy boiled sweets - gord

k

[macka]

thanks man, I'm hitting a junk yard on the weekend, I'll look for a good flywheel for ya.

[Smokey Eddy]

So my AAZ is ready to be dropped into the car.

pics or it never happened?

oh and Macka, i didn't have room in my back pack for the sweets but i can have some mailed to you direct from my cousin, friend or aunt.  =P
its easier to ship food than it is to bring on a passenger plane.

[burn_your_money]

pics or it never happened?

You said it!

[Smokey Eddy]

When you have the block upside down and the oil pump sticking out of this thing it actually looks pretty cool.

I cleaned the pistons up with a sanding flap wheel on my dremel. I also didn't break any rings this time!!!

I had the crank hot tanked.

This is supposed to be the crank nose after it was "fixed" but it didn't look any different at all for $40...

I was happy to still see the stone marks after i honed the cylinders. there is no lip at all... Tyler, do you know how many km is on this bore?

All nice and black. but where is the turbo?! :O

1 Piece at a time. The cam and IP gears unfortunately got some surface rust in their down time. The faces are painted though. See the oil cooler sandwich plate?

These are just for "good measure". $180 for the pair brand new in the box i couldn't say no.

This wasn't the finished product. I ended up porting them quite a bit more to match the size of the ports in the head which i also enlarged. I really wanted to get a shot of the ports on the head which i was really happy with. i didn't quite get a mirror finish on the exhaust ports but all of the ports are MUCH larger than before. I gasket matched them based on the grime stains where the gasets were not covering. But more so i carried the width of the opening down close to the valve and i smoothed out and widened where the ports make that 90 degree turn down to the valves.
I then lapped all the valves very vigorously with my drill and a piece of fuel line and replaced 1 valve that got bent.

[Smokey Eddy]

working on this now ...

Will my propane torch be hot enough to heat the bolts in the hot side of the turbo to get them out?

[RadoTD]

We need a thumbs up smiley on this forum!

You know you're taking me for a ride once it's alive, right?

[Smokey Eddy]

I certainly hope so!!

[theman53]

If you take the wastegate apart I would love to see what is inside it. I am really worried I killed mine. Great job and good luck.

[Smokey Eddy]

I want to make that DIY pressure regulator thing that goes in the pressure line from the cold compressor housing to the waste gate. I want my waste gate to start to open at 20psi and be wide open by 22psi.
I also know that the dust cover is missing in my photos and yes, that crank nose did slip but that's supposed to be "fixed" from the machine shop. the gear still wiggles slightly on it though.
Never the less, im not going to be running a serpentine belt so i shouldn't have the same issues that most AAZ have with their pulleys & crank gear.

[burn_your_money]

I hate to say it but I'd be worried about the crank nose. It should basically be an interference fit. It looks like they just cut the notch on top of the old keyway which is not a good idea. It's best to do it 180 out. You are using the TDI gear right?

I have no idea how many kms are on the block. I don't even remember who I bought it off of so I can't ask them.

Your exhaust manifold is going to stink when that paint burns off

[Smokey Eddy]

Well the paint is supposed to be rated for 1200F...


and i agree. I was not impressed with the machine shop job. I got it done through a friend for $40 too so i can only blame my self... I thought they were going to shave the nose down and cut into the nose of the shaft to extend the key how ever much they shaved off the crank nose.
And no, im not using a TDI gear. I'm using an "almost" brand new half key gear. (like on the AAZ and 1.6's)

The plan is going to be to use a new bolt and cover the entire bolt with permanent locktite.
I can't really afford all new bottom end bolts to have it machined. New valves are cheaper at $10 a valve than those dang bolts anyways.

I spoke with a VW tech guy last week and he said if i wasn't running a serp belt it shouldn't be a big deal. He said the 1.6's rarely if ever slip. Something to do with vibrations.

[burn_your_money]

Well let's hope you never have to take it apart.

I was thinking of switching to a serpentine setup but I think I'll keep my v-belts. I don't find them that troublesome.

[Smokey Eddy]

Yes, the V-belts aren't that big of a deal so long as the pulleys are not wrecked and they are under the correct tension.
i blamed the V-belt design for ages until i got a tensioner that worked.

[Smokey Eddy]

The going got tough! not really, im just lazy. But hey, three dubs in 1 picture! RadoTD's corrado is behind the white golf.