AAZ rebuild (broke down in Maine)

[RockOcean]

I recently broke down in Maine from overheating my AAZ 82' Westy. I am staying at a mechanics shop so this is a huge help. Just a little info 3 months ago I changed the radiator, retro fitting the newer style. After changing that I realized the head gasket was the source of the problem. I changed that, and it ran fine for 2 months driving it everyday and then 800 miles to Maine. All of a sudden one day it overheated again - the cap on the expansion tank would not tighten down. So I replaced the expansion tank and figured I would be on my way. Not the case about 50 miles down the road it overheated again - then a couple more times til I knew it was time to get it to shop. 

I decided to tear the motor down completely. Luckily I have a hot tank right next to the van so the parts are all clean :- )

-The head has been checked and is warped .006 also has a crack but does not leak. It was a 1.6 head I plan on replacing with a 1.9

-Cylinder number 3 has a lot more carbon build up then the others, also on the bottom of the injector.

-Cylinder number 2 has a small or maybe big chip on the edge of the piston crown.

-All pistons have slight valve marks on them number 3 is the biggest.

I will be taking the disassembled motor to the machine shop today to have them check everything out. Gonna have them machine the crank for an AHU pulley as well.

Here are some pictures:

Chip on #2
IMG_8625 by RockOcean.com, on Flickr

Chip and side wear on #2
IMG_8626 by RockOcean.com, on Flickr

Carbon build up and valve imprint on #3
IMG_8627 by RockOcean.com, on Flickr

Crank Snout
IMG_8631 by RockOcean.com, on Flickr

I am posting on here because I want this rebuild to be done right and hopefully not again for a long time. So if you could give me your opinions on what I should do, and what parts to use I would really appreciate it. If you need anymore pictures of anything let me know and I will post them

Thanks so much,

Ryan

http://www.facebook.com/FreeRockOcean

[RockOcean]

Got the block report back from the machine shop:

Piston is .20mm smaller and the Bore is .30 bigger then Bentley specs.

Does this sound right? I am going to get another machine shop to check it to make sure.

[theman53]

That can't be correct. Maybe .020 and .030 but tenths is huge with these. The .003" would be the wear limit for overbore to the .001" spec.
The pistons look like they have been running with bad injectors/nozzles. I would get those pop tested and rebuilt.

[libbydiesel]

If those specs are right for the pistons and bores, then you were more than FIVE TIMES the wear limit.

[RockOcean]

Well I guess I will be questioning the machine shop tomorrow. Thanks guys, you know anywhere I can find a aaz valve cover?

[CrazyAndy]

Well I guess I will be questioning the machine shop tomorrow. Thanks guys, you know anywhere I can find a aaz valve cover?

If you mean gasket, then RockAuto sells 'em, just look under Canadian options and use around a 1996ish jetta.  Beck/Arnley, if you have preferences.

If you need the cover itself, I do have an extra.

[RockOcean]

I need the cover, I will take it.

Do you have the pvc valve connector as well? The 1.6 cover has an outlet that a hose goes over and clamps to - where as the 1.9 cover has a hole that it pops into. Thats how it looks to me, correct me if I am wrong.

[RockOcean]

So the mis-communication with the machine shop has been solved.

The pistons are .002 worn and the bore .003

What would you recommend I do at these numbers? I am thinking standard size pistons with new rings and just honing the bore. Or would it be better to get 80mm pistons and get the block bored to fit them?

As for the injectors, is the carbon build up the sign for the bad injector? Because the #3 cylinder has a lot more noticeable carbon build up, would it be okay to just change out that injector?

[libbydiesel]

The wear limit on piston to cylinder clearance is 0.003.  If you were to hone, you would be past that on just cylinder wear.  To be in spec you will need to bore and use new oversize pistons.  Be sure the shop doing the machine work is familiar with VW diesels and that they are willing and able to hit the 0.001" piston to cylinder clearance.  That is tighter than most engines and many machine shops will want to bore to at least 0.002" which starts the cylinder already half worn out. 

[theman53]

The pics of #2 were definately a bad spraying injector. #3 could have been or it could have been a valve issue or a compression issue. I would take them all to a shop and have them pop tested or just have them rebuilt with new nozzles. The 4th piston melting down could very well be the injectors being bad and getting too hot in there. I would not run those injectors without knowing exactly what condition they are in, just me though.

I recommend getting the next size pistons and doing the entire thing over. You could put it back together but it will not last as long or it could run like garbage until you pull it and do the complete rebuild. If the bores are at .003 and the pistons are -.002 then that is .005" and soon they will slap especially when cold. If you are not wanting to fuss with it then I would do it now while it is apart and ready to go, but that is just me.

[RockOcean]

Thanks for all this info - feeling much better now about getting this done right. Are my Intake and Exhaust Manifolds from the 1.6 head going to match up with the 1.9 head?

Here is a parts list I have put together if you think I am missing something please let me know. Does anybody know the part numbers for the Crank Bolts, Intermediate Shaft O-ring, and Intermediate Shaft Bearings?

- Valve Cover with mounting bolts (I have had the gasket for 3 months)                                                               50 - 100

- Head   http://shopping.boraparts.com/product_reviews.php?manufacturers_id=32&products_id=32                         750 - 800

- Injectors   http://www.performancediesel.ca                                                                                                125 - 300

- 028 103 383BK    Head Gasket                                                                                                                       $22

- 028 198 012E  Cylinder Head Gasket Set                                                                                                          $32

- 80mm Prothe Pistons                                                                                                                                   $225

- 038 198 155 G    80mm Over sized Piston Ring Set Goetze                                                                                   $60

- Machine Shop Bill                                                                                                                                      150 - 300

- 028105425C Connecting Rod BOLTS (AAZ)

- Crank BOLTS (AAZ)

- 068 103 384A Head  BOLTS (AAZ)

- 028 129 717D    Intake Manifold Gasket                                                                                                             

- 028 129 589B    Exhaust Manifold Gasket                                                                                                           

- 028 198 501    Engine Connecting Rod Bearing                                                                                              $25

- 026 198 491    Engine Crankshaft Main Bearing Set                                                                                        $34

- 026 198 421    Engine Crankshaft Thrust Washer Set                                                                                     $11

- AHU TDi Crank Sprocket                                                                                                                           Free

- 056 905 261 Vacuum Pump O-ring

- Intermediate Shaft O-ring 

- Intermediate Shaft Bearings

- 037 115 220B    Oil pan gasket

- 068 103 171F    Rear Main Seal and gasket for mounting plate

- 068 103 085E    Front Main Seal and gasket for mounting plate

- 068 115 304B Newer style oil filler https://www.getvwparts.com/oem-vw-parts.html                                       $88

- Machine Flywheel for starter                                                                                                                 $50

- Flywheel and VR6 Clutch BOLTS

- 028 109 119P   Timing Belt

- 028 129 713E   AAZ Intake Manifold                                                                                                      50-100

Total is gonna be $1,700 - $2,300

[burn_your_money]

Exhaust manifolds will be the same, but you will want to get an AAZ intake. They have D shaped ports instead of 0 shaped. You can run the 1.6 stuff, but it's risky. There isn't a lot of contact so it'll likely blow the gasket out.

You don't need a cylinder head gasket set if you are buying the intake and exhaust manifold gaskets separate.

[RockOcean]

Ok I see that now - and it looks like its the same size and fitting so I can put my right angle elbow on it. And not have any problems with inter-cooler piping changing. Now I just need to find a AAZ Intake Manifold - anybody got one for sale?

[theman53]

The engine thrust washers "probably" won't need bought. Usuall they are fine. Measure the endplay and see. It is something you will have to do with new ones anyway. I had my machinist measure mine from the exploded 1.6 I have and they measured the same as new. As long as you don't ride the clutch 24/7 I am sure you will be fine on that one to reuse.

[RockOcean]

Alright thanks everyone 

All the parts are on the way. I sent the injectors over to Giles for a check and possible rebuild, he also had a complete head for me. I ended up going with the Prothe Pistons, I wanted the Goetze rings but I could not find them in the 80mm over size so I went with Grants. I got a valve cover from http://car-part.com/ The intake manifold off ebay http://stores.ebay.com/trigonmachinery this guy sells mostly Marine parts but has some really good VW Diesel parts as well. All the other parts I got from my brother, if you ever need common parts he can get them for you. When I get home I am going to make a Vanagon parts section for his page www.urotuning.com.

Two things I do not have yet are Crank Bolts, and Intermediate Shaft Bearings - do these need to be changed?

Any tips and tricks when rebuilding the motor?