Thezorn's AAZ rebuild.

[Thezorn]

I don't have time right now to give actual measurements but hopefully I can offer some insight.  According to ETKA, the crank sprocket for the 1Z/AHU TDI (028 105 263E) is a *different part number* from the ALH sprocket (038 105 263 E).  In your PM you mention that you got the later one.  I have not gotten one of the ALH ones, so I can't confirm that the difference lies there, but I can say for certain that the 1.6TD, 1.9TD (AAZ), and the 1Z/AHU (96-98 TDI) are all the SAME crank nose diameter and the step on the inside of the sprocket matches it.  The only explanation I can offer is the possibility that the ALH crank nose is a larger diameter and you got the ALH sprocket instead of the 1Z/AHU one.  

Well that at least shines a bit more light on the situation. Ill look into it at the dealer today and see what there parts show.

thank you sir.

[GEE-BEE]

IdIparts.com show's this :
http://www.idparts.com/catalog/product_info.php?products_id=1649

GB ??

[Thezorn]

Finally firgured it out. The sprocket I had gotten was the ALH one but for some reason when looking under a golf on the dealers computer the engine code AHU or 1Z didnt come up. After a long session of head scratching we looked under jetta just to see, and viola, there it was. Any ways, got the right one on order so I can get back on track again.

As for my port and polish Ive finished doing the intake ports but do I want to open up the exhaust ports on the head aswell? and what about the exausht manifold?

[lloydbiker]

I just looked at volkswaparts.com, And comparing the pics of old-style (problematic) crank gear, the early TDI (1Z/AHU), and late TDI (ALH) the ALH gear seems to have less space between the pulley mount bolts and the crank hole, than the other two, and as the pulley holes are identical on all, the crank hole must be larger.  

[Thezorn]

Ya it was the ALH sprocket that was the problem. Got an AHU sprocket and it fit perfect. Its at the machine shop as we speak.

[Thezorn]

I have a dumb question, the main caps are labled with numbers 1 to 5 but which end of the engine does the one go to. Does the 1 start at the clutch end or the timing end. No idea why I didnt pay attention to that.

And is there any way to tell what main bearings I have in my car from the part numbers on them? (standerd, overssize or under) besides getting the machine shop to measure them, so i can get some on order right away?

[lloydbiker]

I just looked at the Bentley for a 1.6 TD (the 1.9 AAZ is basically the same), #1 is timing drive end, #5 clutch end, as per norm in a longitudinal installed engine. As for knowing the bearing sizes, on most engines I've had down to the crank (mostly American and one Brit) a standard bearing would have only a part number, and undersized (reground fit) would be labeled -0.010, -0.020, -0.030 near the part #. However, on the VW, if they were German bearings, the undersize might be labeled
-0.25, -0.50, -0.75 (mm) (within .0005" of -0.030" at -0.75mm). You won't get oversize, as that would involve adding material to the crank, leaving less space for the bearings in their bores.

[Thezorn]

perfect, thanks man

[lloydbiker]

Do you have a 'Freewheel' alternator pulley on your engine? The '98 TDI uses part # 028-903-119AA and it fits the AAZ. I think VW got caught with most of their serp belt engines having the crank gear problem, and applied this to all later cars. see http://forums.vwvortex.com/showthread.php?5031715-DIY-ABA-AAZ-G60-VR6-MKIII-Engine-upgrade-Clutched-alternator-pulley-helps-prevent-catastrophic-crank-pulley-fail it tells the story. I called concept1, Calgary, http://store.concept1.ca/store/ and the pulley is ~$90 delivered BC. I've seen prices from $70US plus $45 shipping all the way to $190US plus shipping, and some being sold in US are "made in Canada"   

[Thezorn]

Yes thanks for reminding me, one more thing for the parts list.

[Thezorn]

Doesnt autometer make a 1/8 diameter probe for there EGT gauges? If they do im sure having a hell of a time finding it. Dont most of you guys use 1/8 probes? if so what kind of guages do you have and who makes the probe. From what ive read the 1/4 one I have is to slow reacting

[jpedro]

IVE GOT AN EXTRA ONE FROM MY AUTO METER GAUGE SET IF YOU NEED ONE

[jpedro]

opps sorry bout the caps wasnt yelling lol, but if you want it send me a text tomorrow evening, im working during the day but ya ill be around after 5.....

[Thezorn]

opps sorry bout the caps wasnt yelling lol, but if you want it send me a text tomorrow evening, im working during the day but ya ill be around after 5.....

Is your a 1/4 inch probe or a 1/8 inch probe joe. I have the 1/4 inch one that come with the kits but i guess the 1/8 inch are alot faster reacting

[theman53]

I believe what we have is the micro-1000 from aircraft spruce...I don't think it is westach brand but it is a K type and works will all K types
also it is the 1/8" you are looking for.
http://www.aircraftspruce.com/catalog/inpages/micro1pyroprobes.php

IIRC part # 10-01478