AAZ in a diesel vanagon

[zuhandenheit]

Hello! I've only just registered, but I've been following the discussions here for some time. I post also on thesamba.

My 1982 diesel westfalia is getting a new motor. The 1.6 is very dead.

I have placed a deposit on an AAZ in Canada, and am working out the details. It has a k03 turbo, so I hope not to have to modify the motor mount.

The head was recently rebuilt, so the motor will come to me in a state of only partial assembly (head on, but that might be about all).

I've been trying to get parts together in advance. So far I've bought the following:

DK transmission.

Saab 900 intercooler.

Clutch kit.

New radiator (I had already swapped in a radiator and fan from a '90, and haven't had problems with it, but I think it would be better that I replace the old radiator).

Also, a quick glow plug relay to replace the original, which I understand would not likely be a match for the AAZ glow plugs.

I will also buy a Westach EGT gauge, and maybe oil pressure and oil temp gauges. I will probably also get an oil cooler.

I still need manifold gaskets, maybe an oil pan gasket, a timing belt (continental) and tensioner.

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My old engine and transmission are out of the van. The engine is disassembled.

I would like to be as prepared as possible before I even get the new engine. So, I will swap the bellhousing and input shaft from my old the the new transmission, and clean up and prepare the other parts, which appear to be in ok condition. I would like also to get a bung welded to the oil pan for the turbo return line.

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Here are some questions that I've not found satisfying answers to:

Can I use the pickup tube from my 1.6 oil pump on the AAZ oil pump?

I have a new water pump that I bought for my old motor (has a cast impeller), will it be ok to use?

The only accessories I need are the water pump and alternator. Will it be easy to swap over the v-belt pulleys and brackets, and to use my old alternator?

The engines use the same oil filter, right?

Also, can anyone tell me if I need a gasket for the bellhousing?


I will try to post regular updates and some pictures. I really appreciate any responses. I've been researching this for some time, but there's plenty that I still don't understand. I am somewhat new to diesel engines in general, and Volkswagens, and engine swaps!

[zuhandenheit]

Thanks Andrew!

I'll probably try the Saab intercooler, because I've already bought one, but I'll keep you suggestion in mind.

I found this: http://www.greaseworks.com/store/product_info.php?cPath=24_66&products_id=510

Of course my project is going a little over-budget, but I am not surprised!

Also, would an oil cooler like this work?: http://www.jegs.com/i/Derale/259/15501/10002/-1?CT=999

[zuhandenheit]

Oh, and regarding the pilot bearing:

I guess that I hadn't planned to remove the flywheel. I suppose you are suggesting that I do, and replace the oil seal and pilot bearing.

When you say that the pilot bearing must be installed, do you mean just that I need to replace it, or is there something else also?

thanks again for the help

[zuhandenheit]

Oh, I see! Wow, there's something that I totally missed. I didn't realize that I would need to use my old flywheel!

Well, maybe I should have mine resurfaced.

[dokarex]

take a look at westachs combo gauges. if i had of known they offered boost and egt together thats what i would have gotten it may be a little larger then singles but would take up less space then 2 single gauges. check their web site along with aircraftspruce.

[55eta]

all you need to know on here www.brick-yard.co.uk/forum/

[Greenthings]

The Oil Cooler with a Mocal (thermostatic) addition is one of the most important things you can do with your Vanagon. If you have good engine oil pressure, mount it in the front with quality hose. I've read good opinions ,online, maybe here?) of doing this. Significant increase in cooling compared installing cooler in rear. Custom fabricated duct-work manditory for any significant cooling back there. I have a non-turboed  (45k mile)AAZ in a 4-speed 82' diesel Vanagon. Around 5-6 years now. With-out a oil cooler 67mph(gearing rpm safe limit) temps would reach 260 -270 degrees in hot weather or up long inclines. I tried a Volvo 740 turbo oil cooler for a while (mounted behind right rear axle). Only got temps down about 8 degrees more. Get atleast a 19 row (NON-CHINESE) oil cooler. Your turboed AAZ will make the oil hotter than my #'s. A 5-speed or (air cooled) Highway flyer 4th gear will make you a much happier driver.  Overall temps, engine rpm decibles, and engine life will improve. I'm pulling my beloved AAZ soon and putting it in a Caddy. Just my 2 and half cents.

[bridgetroll13]

Be sure to get the oil pan gasket with the built in windage tray (if it's not already installed). With the engine leaned over so far mine seemed to sling the oil right up the crankcase vent tube. If you really want to go nuts you can buy the one from crankscrapers.com that has the built in scraper but so far the stock part has worked fine for me.

Erik

'82 Westy, AAZ, AAP 5spd

[zuhandenheit]

Thank you for the helpful responses!!

dokarex-- Unless I'm missing something, the combo gauges appear to be more expensive than two gauges. That being so, I'll probably just get the two separate gauges. But if I found a good deal, it might be nice to have the combo gauge.

55eta-- I had forgotten about that forum. I'll start reading it.

Greenthings-- Thanks for the information.

I'm nervous about putting an oil cooler in the front, because I'm concerned that it could have a negative effect on my oil pressure. I guess that I'll need to do some careful testing with both oil pressure and temperature gauges.

I've been planning on using an oil cooler mounted in the rear. I'll probably get everything running first, maybe drive it a little with gauges to see where things are. Then I'll consider cooler placement.

Also, I did buy an aircooled transmission. Hopefully the lower RPMs will help to keep my temps down.

bridgetroll-- Yes, thanks for mentioning that. I did ask the seller if the motor has a good oil pan gasket with a windage tray, and planned to buy one if it does not. I haven't received a response to that yet, but I'll be sure to use a windage tray one way or another.

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I don't have any updates. I'm just waiting on parts. But, again, I'll post updates and questions as I go along. I'm sure I'll have plenty of questions. Thanks again for the help so far.

[Greenthings]

If you don't have a tach in your Vanagon...there's a seller on e-Bay ,now, with some awesome little 2" VDO topcockpit (80's era?) pedstal 1-6K Tachometers starting at $30. They hook-up to the W terminal on your Alt.    Great for the Vanagons. I picked one up this past week. They pivot 360.. There like new with box and instructions.

[srgtlord]

wats the sellers name?

[zuhandenheit]

I sure don't have a tach.

I can't find the tachs for sale that you mentioned. Maybe they were already purchased? Could you post a link? Thanks!

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Also, any comments on this oil cooler? : http://www.jegs.com/i/Derale/259/15501/10002/-1?CT=999

[zuhandenheit]

Oh, and I received my Saab intercooler today. I see why these are popular . . . It fits very well in the space under the side vent.

I used to have a Supra intercooler. It was much larger, but might have still fit in that space. Too bad it's gone now.

[Syncroincity]

Here's where I'm putting mine;



Trimmed the fresh air scoop to place the cooler here, fits comfortably between the grille and radiator. (No a/c condenser)

Getting crowded up there with the AWIC radiator...