Vako's AAZ rebuild

[vako]

yeees  in georgia vw engines are dirt cheap    i will check and file down ring groves to specified size it it will be needen on damagebd pistons.    today i left my old block and new pistons to the machine shop. they will be custom fitted to each bore. mechanic said that with new rings they will work almost as much as new ones and little bit of piston scoring will not affect compression.

so now i'm looking for cheap rings   because my budgs is almost gone after buying new engine and reboring it 

will these rings work for non performance build, for maxuimum 100 000 kilometers?
http://www.hansdieselparts.com/1ZDiesel50Rings.htm

i'm also buying these head bolts
http://www.hansdieselparts.com/068103384AHeadBolts.htm

[theman53]

I wouldn't touch his stuff. I prefer the Goetze brand for rings and anyone else's head bolts are probably better than that. If you are only looking for 40,000 miles I hear the Grant rings are pretty good and much cheaper than the Goetze

[vako]

could you give me any links for rings and head bolts?

[vako]

http://www.ebay.com/itm/Grant-Diesel-Piston-Ring-Set-80-0mm-/360759251022?pt=Motors_Car_Truck_Parts_Accessories&fits=Make%3AVolkswagen&hash=item53feed504e&vxp=mtr

are these any good?


what about payen and beck& arnley bolts from rockauto?  also they seem to have goetze rings for only 8.5$ :|

[vanbcguy]

Rock Auto is great, they sell real parts and tell you who makes them.

[vako]

very good, i will order the parts tomorrow after i get my rebored block from the shop.

i wonder why vw engineers decidet to use 21!!! millimeter hole in the crank. i have 10 mm input shaft and 10x21 bearing does not even exist previosly i had 10x19 bearing installed tehre with steel sleeve. this time i think i will enlarge the hole to 22 milimeters
 with a reamer (a friend of my installed 2.0 petrol engine in his vitara and he has the reamer of the right size...)

the worst thing is that i will have to wait for my bolts and rings for at least 2 weeks (

[vako]

what do you think about installing 1y (1.9 diesel)/petrol rod bearings on my engine?    those are ~0.5 milimeters narrower than my bearings and mahle/king bearings cost 13/15$. also they are avalable in every size 
i hope that i will find main bearings easily , because they are same on gas/diesel engines.

tomorrow i will take my block from machine shop. mechanic said that pistons are already fitted to the block 

[theman53]

I don't know what would happen. 1/4 mm  on each side is nothing really but they obviously did it for a reason. If you got the TDI in your country it should have the mains you seek.

[vako]

yes there seems to be some reason for wide bearings i'l continue searching
i have double checked and gas/diesel main bearings are the same for    1.9-1.8-2.0 engines. the only difference is N4 lower bearing. gas engine bearings come with grooved lower half. in diesel engines all lower bearings are without grooves and holes

[vako]

should i stay away from his bearings too?
http://www.hansdieselparts.com/19Under5CrankBearings.htm

according to part numbers they are manufactured by vw... :S

[srgtlord]

I would NOT trust parts from that supplier

[theman53]

Glyco makes the #4 grooved all the way around. The normal diesel one us 1/2 grooved so I don't think that is it? Usually what you want to stay away from was the integrated thrust washer the gassers had

[vako]

yes i heard that integrated thrust bearing are no good

after measurements i found that "new" crank seems to have been machined previously. -0.5mm on rod journals and -0.25 on the mains. seems like i have missed 0.5mm mark on rod bearings when i has checking them... now it seems to be in good shape and all the journals are in perfect shape (and within the specs) but i think i will still use my crank that does not have machiend rod journals (it must have been machined for some reason.. rod knock or smth like that )


my rebuild costs so far:
head pressure testing and resurfacing - 36$
m12 head bolt socket bit - 10$
"new" short block for pistons - 90$
tdi style spocket - 14$
machining my old block for "new" pistons - 30$

to do list:
1) piston rings and head bolts from rockauto - 60$ (witout shipping to georgia)
2) machining crank to accept tdi spocket -?
3) machining the crank to accept 26 od input shaft bearing - ?
4) checking the crank, if it is worn more than 0.04-0.05 millimeters - if it is out of specs than + 30$ for machining it.
5) new bearings -
6) new head gasket (victor reinz or elring) - 26$
7) crank front, camshaft and intermediate shaft seals - 7-8$ approx.  

[745 turbogreasel]

If you play around in the rockauto shipping  calculator (warehouse A,b,C) enough, sometimes you can find parts that ship from europe.
For me thats a 'what why does it take 3 weeks', but I had to get  new inner fender liners for my friends MKIV, and euro liners were like $4 as opposed to $75  from the US, so even after $30 for shippng we were well ahead.

[vako]

tofday i bought 0.25 rod and 0.50mm main bearings for my crank, just for 29$, on monday i will take my crank to machine shop and that will be another 30$

my rebuild costs so far:
1) head pressure testing and resurfacing - 36$
2) m12 head bolt socket bit - 10$
3) "new" short block for pistons - 90$
4) tdi style spocket - 14$
5) machining my old block for "new" pistons - 30$
6) rod bearings (0.25 mm) & main bearings (0.5mm) - 29$
sum - 209$

to do list:
1) piston rings and head bolts from rockauto - 60$ (witout shipping to georgia)
2) machining crank to accept tdi spocket -12$
3) machining the crank to accept 26 od input shaft bearing - 12$
4) machining the crank - 30$
5) new head gasket (victor reinz or elring) - 26$
6) crank front, camshaft and intermediate shaft seals - 7-8$ approx.

here are the pistons and the rods after first stage cleaning



every cylinder is individually sized for each piston.   npr bearing photos coming soon ))