Thezorn's AAZ rebuild.

[GEE-BEE]

I have blue in stock 105.00 all three shipped with clamp's
red/yellow/black made to order

1.9 aaz breather in any color 27.50

email me at [email protected] for a pic

I have the firewall to head assy  GB171-212-611 E ,21.50

all with clamp's

GB

[Thezorn]

you have an email sir.

[jpedro]

if u need a valve spring compresor i have one.

[Thezorn]

if u need a valve spring compresor i have one.

I actually jusy built one today. Ill show you it tomorrow if you want to check it out.

[Thezorn]

Okay quick question. Whats going on here. I got the TDI sprocket today and compared it with the AAZ one before i took it to the machine shop (luckily). The hole for the crank nose looked alot bigger so I messured it just to see. The opening on the TDI sprocket is 34mm and the opening on my AAZ sprocket is 31mm, same witht the crank nose being 31mm..
This is a problem. Shouldn't they be the same size, or at least closer to it? What will I have to do? Or what am I missing.

Will

[theman53]

What opening? Deep or diameter?

[Thezorn]

What opening? Deep or diameter?

all diameters. and its the measurment of the crank nose diameter and the inside diameter of the sprocket.

[theman53]

I don't know that one. It should end up being a .003" press fit. At 3mm bigger it will not even be a press fit.

I am understanding correctly, right?

[Thezorn]

I don't know that one. It should end up being a .003" press fit. At 3mm bigger it will not even be a press fit.

I am understanding correctly, right?

Yes that is completely correct. I thought it should be a press fit also..? only thing i can think of it that the engine is a 93 built in 92. So it could be different. But it still doesnt make sence since you can do the TDI conversions on the 1.6s also.

all I can say is I dont understand.

[Thezorn]

anyone know whats happening with this? do I have a different crank? or did I get the wrong sprocket again?

[theman53]

No clue on that. i just got a TDI sproket and had it machined. maybe this is why you have had issues all along?

[Thezorn]

Yea. I got a TDI sprocket off an 02 just like you had, but there is 3mm difference in the sprocket inner diameter (34mm) compared to the crank nose out diameter of 31mm. If anyone could measure either there crank nose or a different TDI sprocket so I know whats going on with mine that would be awsome

[Thezorn]

Here is what im looking at.

TDI sprocket.
34mm bore. (the spot where it accepts the crank nose)

and a 16mm bore for the bolt.


AAZ sprocket.
31mm bore. (again where the sprocket accepts the crank)

and a 14mm bore for the bolt.


Im guessing I either have a different crank then following years of the AAZ (since mine was a late 92 early 93 model) or this is the wrong sprocket yet again. If the crank is the difference im thinking of just filling in the bore on the TDI sprocket with weld and getting the machine shop to cut the bore the same style, but at 31mm, so it will fit the AAZ crank.

This ever happen to anyone before?

[theman53]

Your measuring has to be off. I have an 85 1.6 and I believe 1.5 are the only ones with a weird crank nose.
34mm I think is impossible. The 12pt bolt head is 19mm and the flange on the bolt could only be 5mm more at most so it would fall straight through the hole if it were 34mm.
Are you measureing the outside diameter of the sprocket? If so I don't think that matters.

[Thezorn]

Your measuring has to be off. I have an 85 1.6 and I believe 1.5 are the only ones with a weird crank nose.
34mm I think is impossible. The 12pt bolt head is 19mm and the flange on the bolt could only be 5mm more at most so it would fall straight through the hole if it were 34mm.
Are you measureing the outside diameter of the sprocket? If so I don't think that matters.

I wish this was true, but unfortunatley my micrometers dont lie to me very often . Just to make everything clear (or at least try to be) the hole that is 34mm is the one on the TDI sprocket. This hole is the one that should be a press fit, like you were saying, of so many thousandths of an inch. The crank nose which it is getting pressed on to is a 31mm diameter. This in turn gives me 3mm play. I know this is weird, sieng as how noone has seen it before.

Maybe libbybappa has seen something like this, or at least knows what the circumfurance of a normall 1.9tds crank nose is. There has to be a reason for all this madness and im starting to think the crank nose is a different size then it should be.