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IDI Engine
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AAZ rebuild (broke down in Maine)
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Topic: AAZ rebuild (broke down in Maine) (Read 24756 times)
Reply #30
September 04, 2012, 03:44:38 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #30 on:
September 04, 2012, 03:44:38 pm »
Found intermediate shaft bearings here:
http://www.rockauto.com/dbphp/prt,116,SH1209S
Logged
Reply #31
September 04, 2012, 07:10:20 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #31 on:
September 04, 2012, 07:10:20 pm »
I have a valve cover coming but am gonna need these to put it on. Doe anybody have these for sale?
ValveCoverBolts (1) (1)
by
RockOcean.com
, on Flickr
> 028103534A
> cover cap
>
> N 90132603
> hex. nut with washer
> M6 /
>
> 028103536
> concave washer
>
> 028103533
> sealing washer
>
> 028103532A
> sealing ferrule
>
> 028103531B
> stud / also use:
> M6X12 028 103 534 A
«
Last Edit: March 30, 2023, 07:04:17 pm by RockOcean
»
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Reply #32
September 12, 2012, 11:32:47 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #32 on:
September 12, 2012, 11:32:47 pm »
Been almost a week since my last post - waiting on parts. Then finding out I need more parts - then waiting on more parts. So here is what I got so far:
Finally fixed the odometer in the best way I thought - will have to see how long this lasts
OdometerFixxWEB
by
RockOcean.com
, on Flickr
The cheap looking but supposedly better rear main seal
SABOemail
by
RockOcean.com
, on Flickr
Ahhh the neu 1.9L AAZ head this thing is beautiful
IMG_0181
by
RockOcean.com
, on Flickr
IMG_0195
by
RockOcean.com
, on Flickr
IMG_0201
by
RockOcean.com
, on Flickr
IMG_0207
by
RockOcean.com
, on Flickr
IMG_0224
by
RockOcean.com
, on Flickr
Funny my second VW was this Porsche Mint Green color, I want to paint the block this color
IMG_0243
by
RockOcean.com
, on Flickr
Freshly cleaned engine bay, its great when you can sit in it
IMG_9912
by
RockOcean.com
, on Flickr
Neu hood ornament
IMG_0434
by
RockOcean.com
, on Flickr
Here is my custom oil filler/checker
IMG_0461
by
RockOcean.com
, on Flickr
The neu cap didn't have a hole in it for a dip stick since it was only designed as a filler. And my old cap would not fit the neu filler tube due to slightly diffrent threads. Also I needed a more flexible dipstick that would make the bends needed to reach the oil level.
IMG_0454
by
RockOcean.com
, on Flickr
So I ended up drilling the centre out of the old cap and then drilling a small hole into the neu one and glued the old piece on to it. O yeah I had to turn down the top of the neu cap to make it flat.
IMG_0451
by
RockOcean.com
, on Flickr
IMG_0445
by
RockOcean.com
, on Flickr
I then put bigger o-rings on the custom VR6 dipstick so that it would have a snug fit. You can get these dipsticks from my brothers shop.
IMG_0472
by
RockOcean.com
, on Flickr
IMG_0540
by
RockOcean.com
, on Flickr
I should be getting the block back from the shop tomorrow and the injectors any day now.
«
Last Edit: March 30, 2023, 07:25:12 pm by RockOcean
»
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Reply #33
September 14, 2012, 05:02:48 am
Syncroincity
Veteran
Offline
727
Re: AAZ rebuild (broke down in Maine)
«
Reply #33 on:
September 14, 2012, 05:02:48 am »
IT'S SO SHINY I'M GONNA DIE!
Great progress and pics, keep 'em coming! I love the oil dipstick, very creative.
Logged
JC McCavitt
'86 Syncro GL Camper AAZ
'98 Jetta Wolfie
'04 Passat Variant GLS 4Mo 5MT
Reply #34
September 14, 2012, 10:59:08 am
starrd
Junior
Offline
128
Re: AAZ rebuild (broke down in Maine)
«
Reply #34 on:
September 14, 2012, 10:59:08 am »
When you install that rear seal - REMEMBER
-no lube
-install and let sit over night prior to rotating the crank so it expands and sets to the crank seal surface
Otherwise it will leak
Logged
Black 1996 Passat TDI Malone tune, K03/04 Hybrid, Keyless, VR6 Clutch & PP357's
White 1993 Passat TD - GTD nozzles, Keyless - Giles pump, K14, Intercooler, 228mm VR6 clutch & PP, CTN Trans etc
Red 1990 Corrado - custom chip by
Reply #35
September 14, 2012, 01:05:15 pm
burn_your_money
Global Moderator
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Re: AAZ rebuild (broke down in Maine)
«
Reply #35 on:
September 14, 2012, 01:05:15 pm »
Is that head from Giles?
Hopefully the parts arrive soon!
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Tyler
Reply #36
September 14, 2012, 02:14:15 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #36 on:
September 14, 2012, 02:14:15 pm »
Thanks
First problem has arrived: After torquing down the main caps it wouldn't turn freely so I loosened caps 1 and 2 - turns freely. But when I torque cap 2 it doesn't move freely. Only with all torqued and cap 2 loose does it spin freely. Any ideas? Everything looks good
«
Last Edit: September 14, 2012, 02:19:09 pm by RockOcean
»
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Reply #37
September 14, 2012, 03:09:20 pm
libbydiesel
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3399
Re: AAZ rebuild (broke down in Maine)
«
Reply #37 on:
September 14, 2012, 03:09:20 pm »
The caps in the right places?
Otherwise, pull the crank, measure the hole when #2 is torqued. Measure #2 crank journal. Within spec?
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Reply #38
September 14, 2012, 06:46:42 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #38 on:
September 14, 2012, 06:46:42 pm »
Yes the caps are in the right place and orientation, will check those measurements tomorrow. Thanks
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Reply #39
September 14, 2012, 07:31:39 pm
libbydiesel
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Re: AAZ rebuild (broke down in Maine)
«
Reply #39 on:
September 14, 2012, 07:31:39 pm »
For the dipstick, measuring at the block port with the 83+ dispstick/tube style I showed earlier is much more accurate. Measuring at the extreme rear corner of the pan means that any slight variation in levelness causing a significant change in the reading. That's why I recommended going with the later style.
To keep the odo gear in place I have pulled the gear off, put some dimples in the shaft using pliers and then superglued it back in place. I'm afraid that the added screw will shred the gear long term.
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Reply #40
September 14, 2012, 11:17:58 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #40 on:
September 14, 2012, 11:17:58 pm »
I would have done the 83+ dipstick mod but my funds are very low and I already ordered the new style oil filler. I actually carry a full size level in my van and always check to make sure the van is level when I check the oil.
I found the reason to my crank not turning freely was due to the wrong or un level bolts. The bolts that were in it originally were the fully threaded newer style bolts and the new ones I got for it where the older style half thread. There is a guy down the street that owns a operates a machine shop mostly rebuilding air cooled motor. His shop is amazing and his workmanship world class, so I told him my problem and he said to leave it and he would come down later to check it out.
We put a dial indicator on the crank journal (I may be using the wrong term here) and the crank was spot on. He them said to torque it down and turned it even tho it was jamming just so he could see what kind of mark it would make on the bearing. Sure enough it left a wear mark on the bearing. After a bit of thinking he then questioned the bolts, so we torqued down the original bolts. With the original bolts it spun almost as it should but still had a little deviation at a certain point. So then he suggested using "emery cloth" to clean the inside of the cap. Sure enough after that it was spinning freely.
My concerns are with this little bit of wear on the bearing should I change them? And should I reuse the bolts? I am a do what ever the Bentley says type of person and they say not to re use them. But does it really matter? Thanks guys I really appreciate this forum and all of your input.
Here are some photos of course:
I take it that I am going to need to clean the paint off where the gaskets go?
IMG_0573
by
RockOcean.com
, on Flickr
The re bore looking nice - as far as I know.
IMG_0582
by
RockOcean.com
, on Flickr
IMG_0586
by
RockOcean.com
, on Flickr
Prothe Pistons with Grant Rings - so much fun filing these rings down to spec. ha
IMG_0604
by
RockOcean.com
, on Flickr
Its always gotta be something when working on an engine this time it's that damn #2 cap
IMG_0608
by
RockOcean.com
, on Flickr
Here are the wear marks that it made when turned with the new bolts torqued down.
IMG_0614
by
RockOcean.com
, on Flickr
These are the bolts, the ones that were in it the newer style on the left and the never used before older style on the right that binded up the crank.
IMG_0638
by
RockOcean.com
, on Flickr
«
Last Edit: March 30, 2023, 07:33:50 pm by RockOcean
»
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Reply #41
September 14, 2012, 11:26:38 pm
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #41 on:
September 14, 2012, 11:26:38 pm »
No Giles did not want to sell me his cam with the head. So when I found out my cam was no good I decided to order a complete head from here:
http://shopping.boraparts.com/product_reviews.php?manufacturers_id=32&products_id=32
But I did get my injectors back from him yesterday :- )
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Reply #42
September 15, 2012, 10:35:11 am
CrazyAndy
Veteran
Offline
739
Re: AAZ rebuild (broke down in Maine)
«
Reply #42 on:
September 15, 2012, 10:35:11 am »
Gee Rock, if you had only let me know that a Cam was all that held you back on Giles' head I would have offered my used one along w/ my VC. Hopefully getting a complete head from Smokey Eddie soon so i con't need it. Buy ey, that head looks too damn beautiful to pass it up!
I'd clean off some of the paint on the gasket mating surfaces, or at least smooth with finishing sandpaper discs for a smooth surface.
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Reply #43
September 16, 2012, 11:30:51 am
RockOcean
Junior
Offline
136
Re: AAZ rebuild (broke down in Maine)
«
Reply #43 on:
September 16, 2012, 11:30:51 am »
Is there a definitive answer for replacing the main cap bolts? The Bentley says you don't have to so I assume that is right? Right?
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Reply #44
September 16, 2012, 11:39:31 am
burn_your_money
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Re: AAZ rebuild (broke down in Maine)
«
Reply #44 on:
September 16, 2012, 11:39:31 am »
I have seen at least 2 AAZs that blew apart because bolts weren't replaced that should have been. Like rod out the block blown apart. I wouldn't chance it. Guilianot is one. Although, his might have been rod bolts...
Definitely mains
http://www.vwdiesel.net/forum/index.php?topic=10690.60
«
Last Edit: September 16, 2012, 11:44:03 am by burn_your_money
»
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Tyler
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« previous
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VWDiesel.net The IDI, TDI, and mTDI source.
»
Engine Specific Info and Questions
»
IDI Engine
(Moderators:
malone
,
burn_your_money
,
Vincent Waldon
,
theman53
) »
AAZ rebuild (broke down in Maine)