OOPS part 2 from across the country

[srgtlord]

I lost my brakes a week ago after hearing a loud pop , thinking it was my master cylinder because I still had brake fluid. I drive about 30 miles that day, only to discover my rear brake cylinder had popped, seized in the open position and my brake shoe exploded

[theman53]

I have time now to order from wherever. It is NOT good. My decision now is do I quickly build a 1.6 and find a head or build an AAZ?
I will post pics as soon as it uploads. Looks like the precup came loose. I had it peened and the head was professionally built. I haven't even been running Giles pump as it is at his place. I am running an N/A pump that I couldn't even make 15lbs of boost with. I have been running it for the last couple weeks.

I guess the simplest solution is the 1.9 AAZ. Does anyone know if the 1.9 TDI and IDI rings are interchangable? I am going to try and do this as cheap as possilble, since sparing no expense hasn't worked out and I need the car ASAP.

[theman53]

BTW, thought it was an injector as it had just started to make a funny noise. No knocking, so I shut it off and restarted to see if it would do anything. Started right up and then went bang, I shut it down and got it towed. I figured it would not be good and I was correct. Piston is cocked in the bore.

Chris, I have no love for ECS or Black Forest Ind. as far as that is concerned, but I would still possibly buy from them.

[guy plain]

thats just fricken nasty lookin!!!!

[410]

Wow that really sucks.  If you need anything for your aaz let me know.  I have pistons, rods, injectors, injector lines, etc...  I'd be more than happy to help you out.

[theman53]

I just pushed it outside and had "oh" moment...

How can #3 be at top dead center when #1 and #4 are too??? I think the rod may have went into the head as the precup wasn't floating around it is jammed waaayyyy up into the head, probably into the coolant jacket as my HG was fine but I lost all water. And there is no mark on the HG as to show the precup falling out. I am not as worried about this engine as I am getting another one done, so I won't have any news on that for a while.

I am pulling apart my aaz engines now and going to get them to the machine shop to measure to see if I need to bore or not. I would like to throw one together as quick as possible.

Couple questions on aaz: Do they take the same bottom end gaskets and bearings as the 1.6? Also can you use TDI rings if I don't have to bore, as none of my parts suppliers like this aaz engine. Can I use the timing cover off of a 1.6? If not I need some timing covers for my aaz engines. Can I use the timing belt and tensioner from a 1.6 on the aaz? I may also need an aaz intake, but this is extreme budget build so I will probably use the 1.6 one.   Basically, is everything useable from engne to engine?

Any charity is always excepted. Christmas shopping has been done thankfully, or the kids would probably be hating Christmas right about now.

[410]

That is a big "OH" moment!  I never noticed that at first.  The intakes are different since the aaz uses D shaped intake ports like the tdi.  I have an ahu intake and an aaz intake if you need one.  I'm not sure about the covers though.  

The aaz engine block is a little taller so one out of the two covers might fit.  I have ahu covers that should work.  

All bearings and gaskets are pretty much the same except for the intake gasket, valve cover gasket and oil filter housing gasket are different.  

The 1.6 tensioner should be fine but the aaz belt might be a little longer.  It should be.

I think you might be able to use tdi rings but I'm not 100% sure.  I have both at the shop so I'll check tomorrow.

I can get pretty much anything you need from my parts supplier so just let me know if I can help.  May your 1.6td rest in peace.

[R.O.R-2.0]

damn it jim!!!

you know what? i just dealt with loose pre-chambers. the TD head i put back on, when i pulled it off the block, 2 pre-cups fell out..

i took a center punch to the bores to make them tight again.

kinda getting a bad feeling about my fix job now..

[burn_your_money]

Timing belt is the same AFAIK. The IM pulley is smaller to make up the difference.
You can use the intake if you are running no more than stock boost. I would be a bit worried about it though.
Everything AHU should swap over. I don't know about the rings though.
The tensioner is the same IF the head is an early one with the smaller tensioner stud. The inner TB cover will be different depending on the tensioner stud as well. It's a simple mod to the cover if you get the wrong cover.
The AAZ is like the 2.0 ABA compared to the earlier 1.8 8vs. Most gaskets are the same but the vacuum pump is different along with the o-ring.
Not sure what else off the top of my head.

[CRSMP5]

i have never beleived in removing pre cups from a head.. so that sux...

the machine shop bob has used for years always used a large belt sander to surface the diesel heads so no pre cup issues or removal..

anytime they put a new belt on it bob would donate a scrap head to run on it to make it not so rough.. he been using this place since the 70s...

if you need a good 1.6head.. solid lifter.. i got one with my toaster in the back.. cannot say its good.. but see nothing to make it bad either.. was retaining it on my shelf for the next time i needed one.. aka still have 2 1.6 i use.... and well good shelf keeper IMO.. but for you.. id help out.. last one i had to buy when i dropped a valve one night was $250...

id pay 100% more on a gasket vs ecs.. i refuse to give them any money.. and all i wanted was a clearances shifter knob.... and refused to pay their 35$ shipping.. on a 10$ part.. and they would not let me come pick it up as at most id have 15 in fuel tolls to pick it up..

i beleive the aaz and tdi rings same.. but him checking his store for exact best..

my tdi rebuild gaskets and such at cost were kinda high vs a 1.6.. rember new rod and crank main bolts.. they all streach and stealership bend over grab your ankle prices.. and with the broken aaz block issues i keep seeing.. do not skimp..

the seals are the same as 1.6... but the teflon ones cost lots more.. and supposedly last longer.. BUT be warned... i had to use a normal seal for the intermediate shaft.. after ruining 2 teflon ones i gave up.. and the rear main seal takes talent.. but with its included white thinggy was pretty easy to install.. just no luck clearing the lip of the im shaft.. kept catching it.. even with shaft in hand.. aka my 2nd attempt.. LOL..

before you pull it off the stand dump 2-3 quart of oil in it.. with a think 12mm socket on top of oil pump.. a 1/2" drill.. prime it real real good.. look at all seals and you will see if any leak.. mine ran a good 10 min checking for leaks... and i knew the lifters and everything else had oil pressure and supply at that point too..

how i tested them teflon seals.. and knew my 2nd botched attempt failed on the im shaft.. but rear main was tits on.. too big a pia to pull tranny to fix that..

the timming covers are different.. the injector lines are different.. intheory the 1.6 belt should work as long as you have the smaller im shaft pully..

just rember.. skimp no good. unles you fixing the 1.6... to build the aaz.. spend the coin.. my tdi rebuild with nozzles and all was a good 1200 part thing.. me rebuilding 1.6 in car.. 200+head+ used piston/rod... so... i spent lots more on tdi.. but i also did it all with upgrades..

[theman53]

Well I have dad's 97 honda to drive for work if needed. I do have the smaller stud for the aaz head. I don't know if my guy can rebuild it in time so I may run it as is. Sucks...I was thinking about upgrading this and that, but now I just need something to run. I drive about 100 plus miles per day for work so if I have to drive my truck at 13 MPG which I dont even have that option now as the brake lines are toast, it cost me more per day than almost a week. I have a 1.6 block but no head to bolt on. Let me know what you would want for that head as I may take it and build a replacement block just in case.
My wife is UBER pissy as I told her this 7,000.00 car would last at least 4 years for me...crow under glass is all I am eating.

[maxfax]

I got a couple mech lifter 1.6 engines here I could swipe a head from if you need..  Hell I'll loan you crack bunny's new engine, I don;t seem to be getting much done with it.. 

[CRSMP5]

call me tomarrow... redoing one in car is a 1 day max job... need to see whats up with 3 though.. i expect broken piston bent rod.. need to get that out and see how the cylender wall is.. if it can be honed up.. a set of rings.. bearings.. used rod/piston.. head your rollin again... ive done that on my 81 coupe when it dropped the valve of the unknown used engine i put in it on the build 3k later... 

ALSO if that engine to be reused.. the crank bolt needs removed and redone.. i missed this when i dropped a valve.. and a year later had a weird clatter and well it was loose.. nothing hit.. just some red loctite and crank pully.. was not the issue.. the pump failed and #3 lost its pressure.. still need to take that pump apart to see whats up..

[theman53]

Good call. I will drop the pan and see if the crank is beat up. Then check out the cylinder walls of 3. 1,2, and 4 look new almost. Then get ahold of maxfax for a head if needed.

[theman53]

All I do is think about this. What happened and if I rebuild it how will it not happen again? I looked at some of the build pics and it looks like the precups were machined flat with the head. I looked at the cyl. that weren't messed up and they are flat. They do not protrude down at all. The machinist who I took my block to said he makes them stick out in all his IDI engines at least .002" so the HG has to crush them in there. I don't know what happened, but if the precup came out I think this was partially the fault.