Thezorn's AAZ rebuild.

[Thezorn]

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

Okay cool, thats what I figured.
Ill see if I can get a video tomorrow. Only thing im having problems with now is that my fuel filter is spitting out tones of air. I remember reading something about how the return line plastic thingy has something to do with air getting into the system.

Just to be sure I changed the lines that got between the tank hard lines and the fuel filter with clear fuel line to make sure that no air was getting into the system there, luckily none is. Could it be that the filter still isnt full of fuel? It was about half empty when I stored it..
But the engine has ran enough for me to think that the filter should be full of fuel by now?
You guys have any ideas?

[Thezorn]

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

Do you remember off hand what if you had to splice it into and exsisting wire in the harness? or was the little slot in the harness empty?
Im having troubles getting the tach to work.

[RadoTD]

See the PM, and I just spliced it into the wire coming from the fuse box to the cluster, there was a wire already there

[vanbcguy]

Okay cool, thats what I figured.
Ill see if I can get a video tomorrow. Only thing im having problems with now is that my fuel filter is spitting out tones of air. I remember reading something about how the return line plastic thingy has something to do with air getting into the system.

Just to be sure I changed the lines that got between the tank hard lines and the fuel filter with clear fuel line to make sure that no air was getting into the system there, luckily none is. Could it be that the filter still isnt full of fuel? It was about half empty when I stored it..
But the engine has ran enough for me to think that the filter should be full of fuel by now?
You guys have any ideas?

If your filter has the plastic tee on top that the return lines pass through then that'd be where I start looking.  Problem #1 is they can crack / leak / fail to seat properly on the filter.  The retaining clip isn't particularly brilliant in my opinion and probably has a fair bit to do with problems.  You can try slathering some vaseline all over the seal and then putting it back on, purely for testing though.  The diesel will dissolve the vaseline pretty quickly.

Problem #2 is that it is a recirculating valve, so any air that DOES get in there will continue to get circulated back to the filter again until the fuel temperature gets high enough to close the valve.  Total PITA.

My advise would be to replace your filter with one that doesn't have that feature - the '85 filter seems to be the one:

http://parts.autopartsonlinecanada.com/parts/apocanada/wizard.jsp?year=1985&make=VW&model=JET-D-001&category=E&part=Fuel+Filter

Then just connect the return lines together.  No more air circulating!

[R.O.R-2.0]

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.

  TWINS!

[Thezorn]

Okay cool, thats what I figured.
Ill see if I can get a video tomorrow. Only thing im having problems with now is that my fuel filter is spitting out tones of air. I remember reading something about how the return line plastic thingy has something to do with air getting into the system.

Just to be sure I changed the lines that got between the tank hard lines and the fuel filter with clear fuel line to make sure that no air was getting into the system there, luckily none is. Could it be that the filter still isnt full of fuel? It was about half empty when I stored it..
But the engine has ran enough for me to think that the filter should be full of fuel by now?
You guys have any ideas?

If your filter has the plastic tee on top that the return lines pass through then that'd be where I start looking.  Problem #1 is they can crack / leak / fail to seat properly on the filter.  The retaining clip isn't particularly brilliant in my opinion and probably has a fair bit to do with problems.  You can try slathering some vaseline all over the seal and then putting it back on, purely for testing though.  The diesel will dissolve the vaseline pretty quickly.

Problem #2 is that it is a recirculating valve, so any air that DOES get in there will continue to get circulated back to the filter again until the fuel temperature gets high enough to close the valve.  Total PITA.

My advise would be to replace your filter with one that doesn't have that feature - the '85 filter seems to be the one:

http://parts.autopartsonlinecanada.com/parts/apocanada/wizard.jsp?year=1985&make=VW&model=JET-D-001&category=E&part=Fuel+Filter

Then just connect the return lines together.  No more air circulating!

Perfect Ill try and source one of those badboys locally today, thanks.

[baldone]

Twint turbo

[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.

  TWINS!

Twint turbo

Compounds

On a side note, the turbo was puking out oil from the exhaust side since I had it on a slant and completely forgot that it was going to leak. Sooo..Engine came back out after about 30 mins of cursing and calling myself an Idiot. Got it mostley figured now, Had to make a new motor mount and bracket. Hopefully have it all back in and going today.

But if it leaks oil again....anyone want a free car?

[trav1856]

Free car you say? *perk*

[rallydiesel]

If it's not leaking then it must be low on oil. 

[RadoTD]

Oil leaks are just your car marking it's territory!

[J Z]

I prefer to call it ''slowly changing oil'' instead of ''oil leakage'' 

[Thezorn]

If it's not leaking then it must be low on oil. 

Hahah yea I think thats how its gunna be!
Its almost all back together. Ill get some pics of the motor mount and such if I can later.

[Thezorn]

Well, there is still a few oil leaks I need to deal with.. Somehow forgot the oil filter housing gasket when it was all going back together
Also having problems with the oil drain for the second turbo. How high is the oil level supposed to be in the pan when its full? My drain bung is pretty well as high as it can be on the pan but It is still somehow under the oil level. The oil flows fine for like 2 minutes while the engine runs but then it seems like once the drain line fills up it starts to back up into the turbo and leak out of the exhaust side into the DP.
It alsmost seems like its creating some sort of sump though. When I check my dip stick it is right at the lowest notch.
I think I might try and hook the drain up to the hole in the block that the K14 is draining into and see if that makes a difference..?

What do you guys think?
Im sorta scratching my head at this point.

[RadoTD]

That's weird...
My bung is below the oil level as well, but I haven't had any problems with it backing up the line. What size return line are you running and does it run over the CV or under it? If it's running over the CV with a 90deg fitting, you might be getting backed up at that fitting