more aaz 1.9 td problems.

[hodgy_7]

hello again  i havnt posted for a while as my car has been sat for  months and months but i finaly got motivated and started taking it apart.

after taking it apart i have  found the usual cracks between the valves and if there is suposed to be a locating pin on the cam pully it  isnt there any more..oh and very slight contact marks on 2 and 3 pistons 2 being a little worse than 3.

i will be taking the crank pully off soon for an inspection.

the other thing was i couldnt seem to line up the tdc mark on the fly wheel  every time it came around  the pump and cam were equaly out of place.(pump and cam were in sync as locked with the tools) so it looks like the timing was out by about 10 teeth but surely  this would cause more damage than a little mark.
any advice on the situation.  is it worth getting the cracks welded in the head.

also  my brother has a spare 1z engine. what bits could(should) i borrow off that  for my aaz rebuild.  will the cam pully go on my aaz.

thanks

[BAM]

Sounds like the crank pulley either spun or the belt jumped.  There is no keyway or pin on the cam or cam pulley, no worries nothing missing.  The head should be inspected for bent valves, guides, damaged lifters, cam shaft damage.  Put a new timing belt and tensioner when reassembling.  Inspect the crank and pulley very carefully as it one of the weak spots on a AAZ engine.  Pictures say a thousand words.  Show us what you are working with.

There are some parts that interchange between the two engines please be more specific what you have in mind.

[hodgy_7]

thanks for the reply  i will try and get some pics  up tomorow  (when i figure out how to)

so there is no pin or key in the cam pulley . well thats good news.   i thaught there was something missing because at  the top of the tapered end where the pulley goes on there is a cut out which looks like  a key  or locating pin should go . at least i dont need to find new pulley now.

as for the 1z parts  it was just a general question  on what i should take off and put on mine.
 

intercooler
alternator

would the turbo on a 1z be any better than the T2 on mine

also would it be best just getting the crank nose macheined to fit the D crank pulley or would it be better to put the whole 1z crank in.

i have a few more questions  but i will wait untill i get some pics uploaded  as you said picture paints a thousand words.

thanks

   

[hodgy_7]

here are afew pics 
digging out the engine

kind of in one bit

slight contact






as i was cleaning bits  i sqirted some cleaner in the turbo bit and before it evepourated  the liquid dripped out of the bit that is circled. i imagine if liquid can get out  then exhaust gas can escape aswell (may be why i used to feel like i was getting gassed when driving it )
is this a problem  if so how do i resolve it.  (disconect the rod  and weld it up  )

oh and here is a video of how the car ran before the engine was removed
vw vento 1.9 td smoke
not great quality  but you get the idea. also it would run smokey exactly like when it first starts. (hot or cold)   unless the coldstart was pulled out.

[84tdrabbit]

that thing you got circled is the wastegate.

it may leak a little oil, but it really doesnt leak much exhaust. if it were a big source of exhaust, there would be black smears all over around it..

[hodgy_7]

i wasnt actualy gonna weld it up.  but i dont think if it was stuck shut it would be that bad would it ? obviously it will make the turbo work harder as it would be boosting longer. but im not an expert  so i should stop thinking

[84tdrabbit]

thats probably a T2, k03 or k14, none of them make much boost. and pretty much need wastegates. i wouldnt want a little turbo like that to over spool and send flaming chunks of compressor wheel down the intake.. a boost controller is the proper way to regulate the boost and make a turbo spool quicker. your wastegate functions right? give it a shot of aero-kroil if its stuck. then grab it with some vice-grips and work it around. it will free up.

[hodgy_7]

yip its a t2.. and the waste gate works  well it opens if i push the lever.  ill just leave that alone then.  ill concerntrate on getting boost after i get the engine back together.

what would be a good upgrade for a t2  that would fit without to much work.    also im planning to fit a intercooler from a 1z engine

[84tdrabbit]

those T2's have the same trapezoid flange like a VW T3 right? if its the same as a K14/24/T3, i would just swap a K24 or T3 on there..

[hodgy_7]

Hi all  back again...  i have a few questions again
i have deemed the original aaz engine dead (un economical repair) as 3 out of 4 pots need re boaring or what ever.
any way
i sourced another aaz cheep in a 97golf  which confused me as i thaught they stopped putting them in around 95ish....  it starts it runs no smoke  (yet)hehe  BUT it is the slightly more modern aaz   it looks like a kind of aaz 1z crossbreed. and has wires going to the pump, which the old one doesnt
question is can i just swop the injection pump from the old one over on to the new engine
change the  manifold and what not as new one has egr and that. then put it back in the old vento and start to get it back to polluting the atmospheer in style

any advice on what to swop what to keep would be greatly apreciated.
thanks in advance

[burn_your_money]

Yes you can swap the pump and manifolds. You likely will need to swap pump mounting brackets as well but that is no big deal. Some guys apparently just run with those pump wires unhooked and do just fine.

[hodgy_7]

thanks  i was wondering if i could just leave the wires off but wasnt sure. i might just put the engine in without swoping the pump and see how it goes. i can always change it later if it doesnt work

[hodgy_7]

hi again peeps 
  Iam still no further forward with this car. but i intend on working on it next week. 
could any one tell me which turbo would be the best to use  the new one has a k03 and the old one is a t2 should i just leave the k03 on and blank the egr or swop it out for the t2
thanks

[R.O.R-2.0]

hi again peeps 
  Iam still no further forward with this car. but i intend on working on it next week. 
could any one tell me which turbo would be the best to use  the new one has a k03 and the old one is a t2 should i just leave the k03 on and blank the egr or swop it out for the t2
thanks

neither turbo is really BETTER than the other..

they both spool early, and run out of breath before the engine does..

the T2 should be a little more boost friendly tho.. 15-20 psi max is all i would ever go with a little turbo like that..

i just swapped a K24 turbo on my TD, and i LOVE it.. spools nice and low, prolly not as low as a K03/T2 tho, but ive never driven an IDI with one of those turbos to know how it performs.. i do know that i LOVE the way my K24 performs with the wastegate unhooked tho.. they have MAGIC wastegates.. leave them unhooked, and they POP open from exhaust drive pressure at around 25psi.. works nicely actually.. the K24/T3 turbos spool nice, and there good for lots of boost.. 30+psi is easy from a K24 or T3 turbo.. good for making power on the top end..

anyways, hope some of what i said helps out..

what are you trying to accomplish with your car? something quick that has instant boost when you stomp on the GO pedal? or a car that has soft bottom end power, and then starts burning the tires once boost hits? my car is the latter of those 2 options.. the bottom end power is soft, but once the turbo lites off, hang on, and start shifting!!

[CrazyAndy]

i just swapped a K24 turbo on my TD, and i LOVE it.. spools nice and low, prolly not as low as a K03/T2 tho, but ive never driven an IDI with one of those turbos to know how it performs.. i do know that i LOVE the way my K24 performs with the wastegate unhooked tho.. they have MAGIC wastegates.. leave them unhooked, and they POP open from exhaust drive pressure at around 25psi.. works nicely actually.. the K24/T3 turbos spool nice, and there good for lots of boost.. 30+psi is easy from a K24 or T3 turbo.. good for making power on the top end..

Now THAT I didn't know about K24 wastegates; is it safe?  Does that cause too much spike or is it quite an even spool to max boost?  Either way I know what I'll be doing with mine when I get it. 

Heard so many good things about the K24 it should be called the 'Jesus turbo'.