Thezorn's AAZ rebuild.

[Thezorn]

Updates finally, havent put any pics up ina while so heres a bunch.

Had to deal with this


So I did this, Im not sure what the cap for the vac booster was made of but it was a b**ch to tap. Or maybe my tap was garbage..


Parts parts parts.

ACT Clutch/pressure plate




Tial 38mm wastegate


Aircraftspruce EGT probe


POR15'd Engine bay, half done


Cleaned K14 and K24 / rebuild k24


Lapped the k24 wastegate valve seat.


I decided to try something new. The K14 is going to be externally wastegated so I deciding to cut the wastegate housing off the turbo. This will give me more room for the K24 to fit in there and also more room for the external gate to go.



Just have to weld up the holes, I guess I will see if it was a good idea

Engine is all together and painted, Has anyone else used HASTINGS piston rings? they are what my machinist got me.




Also got a new inst. cluster with a tach in it. Is there any way to swap the speedo/odometer assembleys from cluster to cluster so I can keep the milage the same?

That mostley it for now, more to come soon!

[Thezorn]

Got the lifters in the head, oil pump in and pan on and a bit more paint done today. I had my camera but luckily my girlfriend had left the sd card for the camera in the computer....or maybe it was me
Tried cleaning the tranny the other day at the car wash but it barely touched the dirt and grim on that thing. What is the best way to clean it?
Im thinking warm water pressure washer and some engine degreaser for my next try.

[myvolkswagen]

Scotts brite pads, super clean, gloves and hours of work. Have fun. It's worth it when you get paint on it

[Thezorn]

Scotts brite pads, super clean, gloves and hours of work. Have fun. It's worth it when you get paint on it

My worst fear haha, I guess it has to be done

[theman53]

I love the black color on yours and the parts of mine that are black. That said I will never paint another thing black on my engine again. I have had an oil leak since the first start and I think I found it last week. You will NEVER be able to tell where fuel, antifreeze, oil, and whatever else can leak out of these is coming from with it black. I love the way it looks, but if I were you and had enough coin for 2 more cans of engine paint I would try to recolor it

[Thezorn]

I love the black color on yours and the parts of mine that are black. That said I will never paint another thing black on my engine again. I have had an oil leak since the first start and I think I found it last week. You will NEVER be able to tell where fuel, antifreeze, oil, and whatever else can leak out of these is coming from with it black. I love the way it looks, but if I were you and had enough coin for 2 more cans of engine paint I would try to recolor it

GHAAA, you dont know how many times I have heard that haha. I think ill run to the hardware store today and snag another colour.

[ktownboostn]

Wow !! watching this one forsure !!

[Thezorn]

Had to deal with this

The little rubber bit there is a check valve.  I suspect that without it you'll end up with crankcase oil/mist getting sucked into your brake booster and possibly wreck the booster diaphragm.  Might take quite some time, tho.  Also, I hope that you made sure that the threads of the new fitting didn't protrude below the surface of the top plate and you didn't leave any burr on the hole.  In either case, the vanes of the vac pump will get trashed.  I recently got a brass check valve from McMaster and installed it into one vac pump that had the nipple broken off.  I haven't installed and tested it, tho.  

Yea I was thinking about that but ive been told that it works fine to do this, and my local dealer cant get me a new one so this was my only option. I made sure the threads of the brass fitting arent poking through also.
I ended up painting a grey "oil leak detection" strip around the head to block sealling area, since ive been razzed about it more then a few times

[Thezorn]

Please report back if/when your brake booster fails in the next year or two.

Will do, thanks

[Thezorn]

Havent had any updates for a while so here are some pics.

This is how the engine sits till I get a welder in the next few days hopefully



Found a link on vortex that said a mk4 cabin filter/housing was "plug and play" with mk3s so I gave it a try.

Sure enough it fits like a glove


Planing on relocating the PS reservior to here:

to free up some space for the intercooler pipes

Transmision got a well deserved face lift.


Started to tackle some of the rust that inhabited my floor



And the oil pressure guage and new cluster with a Tach I picked up from forum members:

I was searching forever for replacements for the crappy stock cluster lights and finally came across "super bright LED.com"
They sell the tiny twist style bulbs that we need for our clusters and they actually work great, they are super bright haha!!

Thats It for now, will have more soon hopefully, when I get a welder in my possesion.

[Thezorn]

This is how it sits right now, still have to put the wastegate on and figure out where my air filter is going to go.

[Thezorn]

Good news, got the engine running today after scrtching my head for about an hour finally realizing I have the fuel cut-off switch wire mixed up with the other guy.
One question. I replaced my inst. cluster that originally had a clock in it to one that has a tach. in it. The tach doesnt work. Im guessing this is beacuse my car doesnt have the wire coming from the "w" terminal to the inst. cluster harness built into it, since it came with a clock.
All I should need to do is run the wire to the right number pin in the harness correct?

Only problem ive had so far is the fuel filter spitting out a ton or air... it will get fixed tomorrow though.

[zagarus]

how have I missed this build! twin turbo setup looks amazing!

[Thezorn]

how have I missed this build! twin turbo setup looks amazing!

haha thanks, hopefully it runs well too. It will be insured and going for its first drive this afternoon.

[RadoTD]

how have I missed this build! twin turbo setup looks amazing!

haha thanks, hopefully it runs well too. It will be insured and going for its first drive this afternoon.

Sweet! Can't wait to hear how yours runs!

You're correct about the W terminal... mine was a black/red wire coming off of the alternator. I've got mine run straight to the cluster harness (U1/06) skipping the fuse box