AAZ in a MK1 Caddy

[shorttimer]

Hi Everyone. OK, so you can see I'm new. I've been lurking around for about 2 weeks now & decided it's time to register cause I've not found the info I am seeking in the search. I recently purchased a complete low mileage running AAZ that I need to stuff into a 81 Caddy. The Caddy has already got a 1.6L non turbo & am quite certain a 020 tranny. I am wondering how many of you are running the same combination and what things were difficult with the switch?

Here's what I noticed when I got the motor home. There was black gunky stuff completely blocking off parts of the EGR & had up to 1/4" of this same gunky stuff inside the intake manifold and inside the intake runners of the head & all over the intake valves. The exhaust valves were clean by comparison.

We all have different uses for our vehicles, so here's my criteria. I'm looking more for mileage and a boost in power from the very lethargic non turbo, so it doesn't take half a minute to get to 50. I'm not wanting to hot rod it but will do things I think will be efficient in it's operation like an inter-cooler & all stainless larger than stock diameter exhaust with v-band clamps. Later, after I get it on the road, I'm going to do some aerodynamic mods to improve the fuel economy. Large gains have been made on another site I've been looking at: Ecomodder.com.

Things in particular I'm concerned with are:
* What clutch/pressure plate was used?
* Is there any 5th gear ratio that's 'too high'? (Too high for the motor to pull easily at highway speed)
* Which exhaust manifold was used, if different from stock, or if you just blocked off the EGR?
* Did you inter-cool? Problems encountered in doing so?
* What size exhaust tube will be good without overkill?
* What mufflers are quiet without robbing power? (I don't want a noisy vehicle.)
* Anything else that may make the transition go smooth?

Thanks in advance for your help,
Shorttimer

[shorttimer]

OK, so I guess this isn't a popular topic, though after going through 20 some odd back pages, I came across a thread where it was done to a MK1, which is essentially the same. I wasn't clear on how the clutch issue was solved. And a few other odds n ends.

[theman53]

Are you familiar with VWs at all? The diesels are a touchy breed. There is an FAQ section, I suggest reading it. With the old VW's you really don't have many options of 5th gear, none of which are too high. What clutch issue?

[shorttimer]

As I stated, I'm a newbie, though I'm in mid 60s. I have found a lot of good info on here, so far, but not everything I need as of yet. I have spent several 100 hrs reading on here searching for anything that may pertain to my humble project. What I have observed, is that a lot of peeps on here assume a person can fill in the blanks in regards to certain aspects of what's involved, without going into enough detail. I'm catching on to the abbreviations. I have 2 manuals & a fairly good selection of tools and am not afraid of work.

I did find a chart for 020 gear ratios & believe the box I have has pretty tall in 5th, but I have no idea if anyone's been in there. It worked fine when I was driving it several years ago with the 1.6 NA. I was hoping there would be some one on here that could give me a definitive answer on what combination of flywheel/clutch/pressure plate arrangement will work with the AAZ/ Mk1 or if it's a straight bolt on. I know I will have to cut the passenger side motor mount, mod the belt cover, use the 1.6 sheet metal on the tranny side and use the MK1 front mounts.

[theman53]

Yep, I believe you will have to cut the timing bracket for the MK1 mount.

All the 020 trans will bolt up to the aaz and "any clutch combo" will work. Meaning if you use all the pieces together it will work, provided you use the smaller 13/16" 24 spline clutch disc. So if you have a 210mm setup that will work, if you have a 190mm setup that will work, if you have a 200mm set up that will work as well. If you have to buy a setup don't buy the 190mm for your aaz as it will be hard on it. What cannot happen is you use a 200mm pressure plate and a 210mm clutch disc...you could the other way around and use a 210pp and a 200 clutch disc. Make sure whatever pressure plate you use has the TDC timing mark.

[8v-of-fury]

Make sure whatever pressure plate you use has the TDC timing mark.

Or make sure to accurately mark your own from another diesel flywheel.

[shorttimer]

That's some great info. Thanks

[stewardc]

I have a Caddy with an AAZ, so here goes.

* What clutch/pressure plate was used?

I used an aftermarket ACT setup and couldn't be happier These engines make good torque when done up properly and you need a grest clutch.

* Is there any 5th gear ratio that's 'too high'? (Too high for the motor to pull easily at highway speed)

No, not with the AAZ. The higher the better.

* Which exhaust manifold was used, if different from stock, or if you just blocked off the EGR?

I used a 1.6 turbodiesel manifold and turbo (Garrett T3)

* Did you inter-cool? Problems encountered in doing so?

Not yet, but space is a big problem with these trucks. I have this intercooler that I'm going to lay flat where the battery is and put a small fan on it.



* What size exhaust tube will be good without overkill?
 2.25" is about all you can get under the truck and fit nicely and that's lots.

* What mufflers are quiet without robbing power? (I don't want a noisy vehicle.)

Can't help you there. I put on the largest Magnaflow that I could find, and it gives a nice rumble.

* Anything else that may make the transition go smooth?

Bolt it in and enjoy it. It's a great swap and they run like a raped ape.

[8v-of-fury]

Straight pipe with some straight through types, maybe a straight through style resonator and a straight through style glass pack.

You kinda picked the wrong engine if you don't want loud The VW IDI diesel is a loud monster, even muffled. Most of the sound comes from the engine bay. lol

[RabbitJockey]

i think techtonics actually makes a 2.5" exhaust for the caddy

[shorttimer]

Thanks All. I started this thread right after I found this site. I probably should have done a whole bunch more reading before I started threads, but oh well. The info I have received has been top notch & I learned a lot & really appreciate the fact that people are nice compared to so many other forums. Just to give a brief up-date, I did purchase a running AAZ with just under 60,000 miles on it. I immediately removed the head to see if any work was required and it looked pretty good, other than it being all gunked up from the EGR. I gave it a port & polish, matched up all the other ports for the turbo to exhaust flange ,etc. Swirl polished the valves & I'm thinking very strongly about sending the turbo out to the guy, in Ohio, that is recommended so highly, as cheap insurance.  I have a T2 turbo. I have a couple of friends who do some of the nicest TIG welding I've ever seen & they're totally on board to help me with this project. I am thinking of a multi purpose radiator (as in another thread) and a 2.5" all stainless exhaust with v band connectors to make installation, and possible removal real easy, if need be. I'm rather intrigued by how some of you fabricate different intakes & it does sound like a good idea. I would really like to find an exhaust manifold that eliminated the EGR, but also fit the turbo in it's stock configuration. Too bad it's such an odd shape (trapezoid). The whole reason for doing all this, in the first place, was to be able to get on the highway & not be holding up traffic 1/2 mile down the road, like the NA 1.6. But I'm hoping it's not too fun either, remembering that when I was riding the Ducati, I would tell myself , before I went out on a ride, that I would really hold it back this time, only to be doing triple digits coming onto the on ramp only minuets later, with a big grin & my 'wish fulfillment devise' (right hand/wrist) holding the throttle to the stop. Oops, sorry, got side tracked. I'm really going for mileage, if I can, with a little fun. These are great little cars, that are fairly simple & cheap to run, and sometimes not so cheap to fix, but well worth it. As I get more into it I'll be taking some pix & sharing them. (we all like lots of pix)

Sorry for being so wordy, but I hope you all have a HAPPY NEW YEAR !!!

[Blue Haze]

As another shorttimer mid 60s Caddy owner that just finished putting a AAZ motor in an 82 Caddy, here are a few notes some of which will conter previous posts here.  First the 210 clutch and flywheel will not fit in the stock bellhousing of the five spd.  Only the 200 mm will fit.  I have a clutchnet stage2 PP and clutch if someone wants to buy it cause I'm stuck with it.  The 200 seems to be holding fine though.  I have only had mine together for about two weeks can't keep the smile of my face when I drive it.  I have yet to get the exhaust done but I'm going w/the 2.25 and some sort of flo thru single muffler.  The magnaflow or I believe it is called a dynamax seems like a great idea.  Currently the exhaust rubs the frame, very noisy.  I suggest you change out the glo plugs I wish I had, now I believe that I have two dead and it will be a lot harder to chg them.  Mine is an A/C car so the air intake took some doing I bought flex hose and a filter from Pep Boys and routed it back across the engine along the firewall to the drivers side.   I did change the t-belt, motor mounts, water pump and v belts with the new engine.  I wish that my installer had changed out all the exhaust manifold bolts and turbo nuts and studs mine are severly rusted and will be a real problem if I ever have to change them.  I also wished that I had tapped the manifold for an EGT gauge when I had the chance.   The oil breather on the valve cover seems to leak at the valve cover somehow I need to correct this.  I'm interested in how one would mount an intercooler on an A/C motor-remounting the battery and installing in that area is the only way I see it.   Good luck I'll be watching to see how you come out.

[theman53]

An 020 210mm clutch will fit in the bellhousing will fit. I have one in my MK2, many also do as well. The 210 was used in gassers as well and some of them have the same trans as the diesels do. It works, you may have recieved an incorrect flywheel or something.

[CRSMP5]

the 190, 200, 210mm od is same on flywheels... else starters would be issue... the differance is the flywheel area the clutch goes in... with 210 even the 190 disk will work... but not other way round..

now there is a 210mm disk thats picky... 16v or mk3 has bigger main shaft.. so that disk no work on older tranny..

and 210mm flywheels changed too... from duel pin to single pin (roll pin for locating tdc on flywheel to pressure plate)... gotta have right pressure plate to match it..

[Blue Haze]

after getting beatup I measured the PP off the AAZ motor it measures 215mm and the clutch is a diaphragm type looks like one from a sm blk Chev.  I don't have the flywheel here from the AAZ but it would not fit in the bellhousing and the starter would not fit either.  215 mm seems to be an odd size but the motor came from Germany perhaps that is why.  Can the year of the engine be determined from the S/N if so can someone tell me the year or direct me how I can find it.  The s/n is AAZ 112218