my mk1 cabriolet aaz project

[dan1.6td]

My built

Now that the planets are aligned correctly and I got every thing I need for my project
It’s time to post it and have your ideas share in the mix
I bought a 1991 mk1 cabriolet 1,8l to mod it as a diesel cause I love torque and smoke 
I have a donor mk2 jetta with a 1.6td and a t3
I have a donor b3 aaz 1.9td with k14

I’ll describe the project and feel free to correct me or suggest other avenue
The car will be subframe with the B3 subframe meaning going with plus suspension for the front and some spacer for the rear
Brake set up gonna be B3 with master and mk3 rear disc setup

motor 1.9td aaz rebuilt+seal+reringed don’t know yet if I oversize(didn’t mesure yet)
NEW CONNECTING ROD AND MAIN BEARING
MESURE HEAD AND BLOCK FOR STRAIGNTENESS
LOWEST AVAILABLE HEADGASKET
ARP HEAD STUD
1.6TD OIL PAN
BLOCK 1.9TD TURBO OIL RETURN IN BLOCK
ALL AROUND NEW GASKET AND SEAL
1.6TD CAMSHAFT
HEAD PORTING
PIN CRANK PULLEY AND DRILL
INSTALL A CUSTOM FRONT BEAM FOR A MOTOR MOUNT
PAINT BLOCK AND VALVE COVER
ALU VALVE COVER OR CUSTOM ONE
TURBO T3 MAYBE A VNT WILL SEE
OVERHAUL KIT FOR TURBO
MOD DIVERTER VALVE TO OPEN AT 25PSI (WILL SEE THAT)
WASTEGATE CONTROL IN DASH AND VALVE LAP
1.6TD EXHAUST MANIFOLD
EGT PROBE INSTALLATION
RADIATOR AND FAN SHROUD MK1
EXTERNAL OIL COOLER

INTERCOOLER
SAAB INTERCOOLER
FOGGER SYSTEM

FUEL PUMP MODIFICATION
1.6TD FUEL PUMP OVERHAUL
AAZ CAMPLATE
ADJUST UNDER BOOST FUELING
SHIMS GOVERNER MODS
1.6TD INJECTORS OVERHAUL
PERFORMANCE PUMP TIMING

INTAKE SYSTEM
INTERCOOLER+ PIPING
COLD AIR INTAKE + SHROUD
SHUT OFF THROTTLE PLATE
mk1 OR HOMEMADE INTAKE

EXHAUST
TURBO DOWNPIPE FLANGE
DOWNPIPE MANDRELBEND 2.5"
COMPLETE LINE MANDREL 2.5" SIDE EXIT DRIVER SIDE
CHERRY BOMB 2.5"

TRANSMISSION

AAZ CLUTCH
AAZ LIGHTENED FLYWHEEL
AAZ TRANSMISSION
AAZ PEDAL CLUSTER WITH MASTER
100MM FLANGE WITH CV JOINT
PASSAT B3 CABLE SHIFTER BOX

So what you think
Did i miss anything?
Any chance its gonna be a fast oil burner?
If interested I can keep the tread posted as it evolved with pics

Dan

[Dakotakid]

Machinist to check and recondition conn. rods if needed.
Wrist pin bushings (if going with new pistons)?

Valve guides. Seats in head maintenance (cut). New valves where needed. Stem seals.

All really fundamental stuff to me (or has this head been newly HONESTLY rebuilt?).
Edit:  Intermediate shaft bearings. Elaborate flush of all oil galleys in block and head (soft plug replacement).

[RunninWild]

why the 1.6td camshaft over an AAZ?

[dan1.6td]

@dakotakid thanks pointing that out head as no rebuild on it got 220 000km and never abused (was a friend of the family car and hes really soft on is diesel) don't even have a oil leak anywhere Will check that when I disassemble the engine

@Runninwild  I've read here a post on custom cam by Dr diesel I think and they said it was the hottest cam with a 1.6na because the epa laws where less restrictive in 85-92 vs 93 and up .I have it on hand so im gonna try it and see for myself .If someone have the spec of the 1.6na , 1.6td and aaz cam Would really be appreciated

[libbydiesel]

Mercury is in retrograde.

If new rings would be at all beneficial it is highly unlikely that the bores are still within spec.

The main bearings are almost always within spec for new parts.  The rod bearings are usually within spec for new parts.  Changing them just introduces more wear patterns to the crank.  Plastigage on dis-assembly.  Replace only if they are out of spec for new parts.

If fitting new pistons (because the bores are out of spec) then before disassembly clean all traces of carbon off the crowns and measure protrusion.  Then measure the pin to crown height on the new and old pistons in order to determine how much to have milled off the block (usually 0.010") in order to use the headgasket of your choice.

I have had very good luck using a true flat surface and 120 grit paper to hand lap the head.  I prefer that over milling as it doesn't mess up the pre-combustion chambers.

Lowest available headgasket??  Get the one that is spec'd for the protrusion.  Doing otherwise is unwise.

Why would you use the 1.6TD oil pan and then the 1.9TD oil return to the block?

Don't pin the crank sprocket to the crank.  After doing so the crank will be weakened, you will be reducing the contact area at the face of the crank and you will need to precisely drill any replacement sprocket that is ever needed in the future.  Instead, have the crank machined to accept the AHU sprocket and get the freewheel alt pulley.

Custom front beam?  Just use the Mk1 mounts (mk1 gasser at timing belt). 

DIY turbo rebuilds often fail prematurely due to imbalance.

Why even bother with the diverter valve?  Just plug the hole.

1.6TD exhaust manifold is the same as the 1.9TD exhaust manifold for the K14.

I wouldn't want a shutoff throttle plate, but whatever floats your boat. 

Mk1 intake has the wrong port shape for the 1.9s.

[RabbitJockey]

id probably stick with the k14 over the t3, i am an advocate for larger turbos, but the aaz k14 is a little bigger than the older ecodiesel turbos, and the t3 doesn't flow that much more air to make up for the slower spool up.  it will definitely be a faster car with the t3 but it will be a more fun car with the k14.  ur doing lots unnecessary mixing and matching with the 1.6td stuff.  keep the aaz pump and aaz pump bracket its much nicer to work with.

[libbydiesel]

keep the aaz pump and aaz pump bracket its much nicer to work with.

...except, you should use the 1.6TD pump top as the AAZ aneroid assembly is a joke.  The pin stinks, the spring is extremely weak and there is no starwheel for adjusting preload.

[dan1.6td]

Night guys
@libby I dig everything you say I've said engine rebuild and a short description but in reality it will be everything that gonna be measured and check
Lowest available headgasket was for the protusion
I was meaning cancel the in block oil return of the aaz and install an external to the pan as per 1.6
For the crank sproket is it just the ahu that fit or all tdi will do?

Custom front beam?  Just use the Mk1 mounts (mk1 gasser at timing belt).  Cause I want a mk2 front mount and maybe install a cross beam depending onhow  it behave handling wise

I wouldn't want a shutoff throttle plate, but whatever floats your boat. Got a runaway once and was a pain to stop

Mk1 intake has the wrong port shape for the 1.9s.So im gonna either tig weld more material to the gasser intake or build a total custom one did someone try to do research on runner length for diesel?

@rabbitJockey Would like to use the AAz pump but was change to 1.6td they even didn't swap the camplate but I got 3 1.6td pump so i just need a AAz camplate no?

[libbydiesel]

AHU/1Z/AFN sprocket but only after having the crank machined to accept it.  ALH or later is different.