81 Rabbit LS AAZ (2023: now tdi-m)

[RabbitJockey]

Ran it with lines in the purge can until the can was half empty and now it's sitting over night

[anhtran]

 The backing plate for it actually says sachs on it, but from what i can tell they disassemble it and install a much strong spring membrane then reassemble it,

[RabbitJockey]

its kind of funny that the spam bot mentioned that, the straps on my pressure plate are torn, luckily clutchnet.com told me they would fix it for free, it sucks that i have to tear the transmission off again, but atleast i wont have to foot a big bill for new parts.

the diesel purge didn't seem to help with the dead spot in power, but the cooler weather did, so i think the issue is turbo inefficiency, the cooler it gets outside the more efficient the turbo is.

[RabbitJockey]

not much of an update since i haven't really gotten to experiment.  but i replaced the clutch again, clutchnet fixed my pressure plate for free even though it was out of warrant, and they also triple strapped it so that i wouldn't tear any straps again.

I've only driven it a few times but now that the temperature is drastically lower the power now really comes on at 2500, i think the power dip issue is definitely compressor surge, i'll be add an intercooler soon which should help to increase flow and efficiency, which should mostly eliminate the compressor surge.

[butch2000]

I am still working at my AAZ into the 81 Caddy swap , question , what did you do for a down pipe off the turbo ?

[butch2000]

also you mentioned in another thread about the crank pulley mod ? what is that ?

[RabbitJockey]

I am still working at my AAZ into the 81 Caddy swap , question , what did you do for a down pipe off the turbo ?

a friend of mine made me a 2.5" downpipe, but it was made for a 1.6td in a mk1 so i had to adjust it a little bit.  Techtonics tuning does make an off the shelf option.

crank pulley mod, the aaz used the same crankpulley style as the 1.6, and it is a common failure point for the crank sprocket to work itself loose and destroy the crank nose, the nose can be modified so that a tdi crank sprocket can be used.  i didn't do this because i believe the issue is caused by the use of a serpentine belt and i used the rabbit v belt set up.  either way the crank nose should be checked, and reinstalled with a new stretch and torqued to proper the proper torque spec.  this is also an issue on g60 engines.

http://techtonicstuning.com/main/index.php?main_page=product_info&cPath=2_11_4_284&products_id=593

[butch2000]

ok , thanks ,I will be using the V-belt accy as well , I wish to keep the factory AC etc , and not cut the front support ,
where did the timing cover need to be trimmed ? to use the V belt accy ? are the 4 speed and 5 speed trans linkage the same ?

[RabbitJockey]

u have to trim around the crank sprocket or else the v belt pulley will rub, if you try to bolt the v belt pulley on to the engine while the lower timing belt cover is on you will see what needs to be trimmed.

4 and 5 speed linkage is different, im not sure what parts are actually different though.  you can use 5 speed linkage on a 4 speed but not 4 speed linkage on a 5 speed.

[RabbitJockey]

this car has kept me busy ever since swapping the aaz in to it.


A few weeks ago i decided to increase the boost to lower EGT's... because lowering the fueling would be no fun. I was headed for a car show and decided to stretch my cars legs on the highway, well when i let off the gas pedal i heard a "fump sound" and saw a cloud of white smoke in the rear view mirror and my car shut off.  I tried restarting it, but no dice so i called a tow truck.

the next day i tried turning it over by hand but it could only turn 20-30 degrees in each direction before it would stop on something, so i pulled the head, and surprisingly everything looked fine inside, which made me more curious.... the injection pump turned over fine by hand and so did the crank and head.  When i looked at the head closer i could see the intake valves had exchanged soot with the pistons... theres a stranger color because i was burning wmo





obviously, it had jumped time, so i assumed it was the aaz crank nose issue, so i pulled the sprocket which looked perfectly fine.





but when i pulled the sprocket out... this little washer fell out with it and then i knew what had happened













so now i have a new set of valves, lifters, valve seals, timing belt, and crank sprocket all on the way.  i'll lap the new valves in as this head and block are in pretty nice shape, the valves are very tight in the valve guides... in a good healthy way not a weird bent way haha.

[libbydiesel]

When I was reading your post I thought it was strange that the cam timing jumped to the advance position.  Crank sprocket slipping or cam sprocket slipping will make it go retarded.  It all made sense when I saw the next pic.  Make sure you use nyloc or stover nuts for the injection pump mounting so that even if they loosen they won't fall off. 

[RabbitJockey]

ah ok, very good idea thanks for the suggestion.  i think this washer was in the upper timing belt, one of the holes that a bolt goes through on a mk3, but is used for the motor mount on a mk1.  something i must have over looked, and now is costing some time and parts haha.  I'm waiting on my 3-4" micrometer to arrive so i can measure the bores also

im thinking of putting the stock pump and turbo on this engine and preparing to sell the whole setup in favor of my recently acquired 3.6l monster.

[RabbitJockey]

so here are the new prechambers i ordered from napa, they are not magnetic

measure as follow:
flange diameter  32mm
barrel diameter  27.85mm
overall height    17mm
flange height     4mm

[MalcolmHoff]

I remember  this was very nice, sucks that the pics are gone now. 

[RabbitJockey]

when i get a chance i will move all of my pictures to another host... it really is sad what photobucket has done to so much good info on the internet.