My slow AAZ rebuild

[gnavs]

I'm really not sure why I didn't post my progress on here, I'd rather get some technical advice than a bunch of "do work son", so here is what I've been up to the last 6months or so

*November 2009*
So after dealing with above average oil consumption, coolant leaking into unknown and potentially damaging areas I've decided to tear into the diesel and start replacing some stuff.  I'll be doing the headgasket, timing belt and, if the funds allow it, slap a new T3 on it as well.  This is my first time getting this involved with anything really so progress will likely be slow but I'm looking forward to learning some things.

Here's how it looked in 08


And here's what it looks like as of an hour ago.....

[gnavs]

Getting the 12 year old crud off of everything was maddening


*January 2010*
Here is my current workstation



dirty engine pics  :shock:

[gnavs]

A few parts were ordered....

*January 23, 2010*


Passat style PD150 intake manifold


Rover boost pin

[gnavs]

Yup, cleaning was definitely time consuming...

*February 11, 2010*

A few more updates, I got the head off and discovered the usual cracks between the valves.  Apparently it's pretty common so I'm not too worried. 
On to the current pictures.  She's a dirty old girl...









definitely looks like I've got some oil blowing by pistons 2 and 3 so a re-ring is in order as well.

[gnavs]

*February 16, 2010*

Out with the old, in with the new 


 

[gnavs]

*February 17, 2010*

Finally got around to getting the valves removed.  I ended up getting the one from Princess Auto and it worked fine.  Next up is getting the head and block hot tanked but I don't know who does this. 
The crank nose will end up getting machined for the TDI pulley.
On to the pics

[gnavs]

*February 27, 2010*

Head and block back from the hot tank.  The block didn't quite come as clean as I wanted so I'll have to get at it with a wire wheel before paint.  The cylinder head has the expected cracks between the valves but I think they'll be alright. 





Meanwhile the pistons are taking a varsol bath overnight.



and here's the color I'm going for...

[gnavs]

*March 5, 2010*
since the hot tanking didn't get the block as clean as I wanted it, I decided to take my dremel and a few sanding drums to it, I think it came out quite nicely.  Decided to go with a cast iron color for paint, pics of the fresh painted block should be up soon

[gnavs]

*March 22, 2010*

My fresh Autometer EGT and boost gauges came in last week.  Also lost my job last week.  Makes for more time but less $$. 

I hate the look of A Pillar pods and also the "look at me!" aspect to them so I decided to put them where they'd make the most sense, right in front of my face.

I used 2" ABS plastic pipe which holds standard gauges ever so gently.  Still needs some sanding and painting but the idea gets across.  It clears the hazard light switch perfectly and doesn't block the odometer or anything.

[gnavs]

And here we are, completely caught up to todays progress   

*June 18, 2010*

Progress once more.
Installed the Rover pin in my injection pump, went in super easy (that's what she said), painted and cleaned up some stuff, and finally got my scratched crank machined. 

It might have been unnecessary but the peace of mind should be worth the coin.


Set of undersized main and rod bearings alongside


Freshly painted and gasket matched PD150 intake


Tapped my exhaust mani for the EGT probe, yes I know it's crooked



went with a cast iron color for the block and head


aaaand cleaned up the valves



up next, hone the cylinder walls and start putting the bottom end back together.

[8v-of-fury]

Congrats senior!! Looookin goood!

[ricosuave]

hey dude, thats looking great

let me know if you ever need a hand, would love to see some of your work in person!

[GEE-BEE]

Got blue or red aaz engine hoses for yah when ready...

I sent your body coolant hoses to the tooler

Wear gloves...

Gb

[gnavs]

Rick! long time no see, I'll definitely let you know when its a progress day

[gnavs]

Yesterday my G60 valve cover arrived in the mail and now I've set about making damn sure it's possible to run it on an AAZ head before I start drilling and tapping.  Can I get confirmation from you veterans?