VWDiesel.net The IDI, TDI, and mTDI source.

Engine Specific Info and Questions => IDI Engine => Topic started by: Smokey Eddy on September 18, 2008, 04:03:34 pm

Title: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on September 18, 2008, 04:03:34 pm
I warn you this isn't very exciting but it tells people who i am when they see me post.

I've had my 1.6td jetta for 2 years now and it's transformed a bit in appearance  and performance wise and plummeted through the floor with reliability and now it's really dead.
It has 350k on it so im not surprised it has enough blow by to cause run aways, cracks between every pair of valves big enough to let coolant in AND require countless items to be replaced. (hoses, wiring, fluid tanks and other expected items)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC02071edit.jpg)
A little background may explain some of my choices and actions. I got this car for $500 in grade 11 and had 1 semester of auto class so i thought i could take on the challenge of keeping a diesel alive. Grade 12 rolls around i take auto again because it saved me tons of money the previous year and that year i got to build a '73 Nova with a 400 in it and race it for the school - fun stuff. I hadn't really done much other than 1 HG. I found a couple sites like this one and thought to my self, "hey maybe this could be a fun car!" (it was really slow) I changed the seals in the pump to accept biodiesel and at the same time did the govenor mod and timing advance spring/shim removal. I ordered some mercedez nozzles and tried to get it to start better from then on. I was told the pump needed to be replaced and it would cost thousands so i said screw that i don't have that kind of money and i need a car to go to work. (It wouldn't start in the first place, hence the 500$ but i somehow managed with the help of a block heater)

SO! here we are, i still have no money (going to university) it's flat black (roller style), coilies on the back (cant get the front struts apart :evil: ), euro bumpers, no rear door handles coz they were broken, bigger tires 165/75/r15 with flat black bbs style rims with chrome studs, home made glow plug relay/switch and it wont start anymore at all no matter how long i jump it for but i can always roll it but that's getting rediculous.

My parts collection!
ARP head studs
1.6 bottom end to be 1mm over bored (Edit: hone now due to lack of funds)
mercedez nozzles
building a 3' down pipe and exhaust (Edit: possibly switching to a 2.5)
volvo intercooler im going to cut in half and tig to be twice as thick and remove the plastic (Edit: looks like its going in the big bumper as is now)
1.9 AAZ head and TDI intake from prothe with EGT gauge w/sender, boost gauge, oil temp and i need a water temp still.
I somehow picked up an oil cooler that is so filthy i dunno what to do with. It needs new hoses.

My plans
Have completely changed....
aaz head + porting (nothing crazy mostly polish)
maybe 25 pounds of boost if the intercooler takes it.

Through my job i have access to a HVLP sprayer so im waiting for my boss to give me a date when i can borrow it for a week or so when the painting season slows down so i've always been waiting to paint it. I think it's going to go glossy black.


It had some embarassing body damage and rust so i just removed all the plastic and did some body work and prepped it for priming
I had to reshape this fender because it was missing one.
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC03646.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC03650.jpg)
as you can see its flat black now. I used the mineral spirit tremclad method because it was easy and fast bust most of all cheap!
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0116.jpg)
My boost gauge set up as seen in a previous post. At least i keep it clean. (Edit: thats gone now i couldn't stand the buzzing of the dial on the pin)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0114.jpg)
the volvo intercooler - its massive
(http://i49.photobucket.com/albums/f279/edmcclung/DSC03679.jpg)
Looks chaulky because i waxed it, i shouldnt have. Also missing the metal bumper.  I had to modify it to accept the euro bumper and had it ground down and painted with rust paint (by the grade 11's obviously) because it was a little rusty. OH and it doesn't have the coilies on in that picture. The rear tires are super super tucked into the fenders now and the ride is really tight with just the back ones in. I didn't wax or buff the gas cap flap (haha some onamatpoia there) so it looks nice and the rest doesnt haha.
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/SSPX0039.jpg)
Pretty sure im using the wrong thickness (3 hole) head gasket because from my recollection the pistons don't protude at all. THAT could single handedly possibly be the cause of the starting issues. Depending on the protrusion with the new pistons im getting (im going to keep using the stock rods because i dont trust the chinese ones fom prothe) will determine the new HG. I sorta hope i was using the wrong thickness HG because then it will put less blame on my IP. This is a photo from the first time i took the head off. The first job in gr.11. (EDIT: Was the wrong HG. need a 1 hole. And no more new pistons anyways so... what can you do!)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC03507.jpg)
No more interesting photo's yet. I have tons of the head and the block without a head on it because i'd never see that before but we all have on here haven't we. All of the above photos are at least 3-4 months old except for the boost gauge one.

Oh and i kept the roof racks of course. I took the locking plates off. they were broken and i was told that the racks couldnt be taken off. Yeah what ever they came off :P (Edit: wish i had a picture of that *ahem* removal :roll: )

still waiting for parts  :(

My project is basically to make a reliable efficient car to go to school and back that will also launch me up the mountains to ski resorts and still start up there in the cold!!!
Edited as of Nov.4 '08
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 18, 2008, 04:07:05 pm
1.9 head, pistons, egt to be here 2 weeks from the 28th! :D
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on September 18, 2008, 04:47:52 pm
Sweet, so explain to me what you mean when you say you are going to cut the IC in half..
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 19, 2008, 12:10:31 am
Cut the IC along the middle row of fins. weld up the bottoms of the top piece and weld up the tops of the bottom piece and cut the backs of the top piece off at the sides and the front off the bottom piece at the sides and tig it all together.

Basically cut the sides OFF and then build new ones piece by piece that would join the top and bottom halves from the inside out so that i can get that first weld on the side closes to the fins.

Does that make sense?
It's hard to imagine but i'd drawn it up
Title: My much anticipated 1.6td/aaz head.
Post by: Dirtrag2 on September 19, 2008, 06:30:24 am
looks like a nice project, you goin' more for power or reliability/economy??
BTW I like the flat black, looks stealth  :P
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 19, 2008, 01:50:53 pm
At night even near a street light it dissapears.
Um... im going for better than stock but as reliable as my own work can provide so..
I'm not going to try and push 40psi into it or anything silly like that or increase the compression more than it needs to be. Nothing extreme. Just what ever my set up would allow and still be moderately reliable
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 22, 2008, 04:35:35 am
I'm getting VERY excited! 20 days until parts get here (hopefully)! :D

ok! what am i missing?
aaz head, 1.6 lifters (from old head), 8mm aaz valves + seats, cam, egt stuff, 1mm over bore pistons, tdi intake... ... ... ... I'm gonna clean the injectors again.
Get my pump timed properly with a gauge. (what should i time to? 1.00 or 1.05 or what? suggestions?)
she's got new glow plugs already!


for the construction of the head am i missing anything?
Im planning on reusing the 1.6 exhaust manifold


Do i have to do anything with the hard lines from the pump to match with the injectors once they're on the 1.9 head?

I also had a question about one of my pictures...
the picture of the block, are those arcs the honing marks? how does my block look from that picture? I don't need to have it planed or anything do i? those arcs are from the machining right?
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on September 22, 2008, 06:14:17 am
I have that same intercooler and the ends are plastic/fiberglass?right?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 22, 2008, 02:09:28 pm
Yeah =( plastic
Im gonna make new ends when i double it up
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on September 22, 2008, 05:25:09 pm
it's always a good idea to prep the surface of the block, but sometimes not quite necessary.  i think i remember jake or someone else using some type of pad to remove gasket material etc. to clean the block.

(http://img205.imageshack.us/img205/7039/100_0831copy.jpg)

if it looks something like that then you're fine :) the vertical lines aren't really a problem if you can't feel them with your nail.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 22, 2008, 05:43:58 pm
Hmmm
no, no honing marks anymore its perfectly smooth. not marks that you can feel with finger nails just perfectly smooth like glass except for near the top you can tell that there is a little bit of a lip where the stoke (the rings go to) ends but not enough to  catch with your nails.

I'll just get it over bored bah may as well. its an extra $500 for the new pistons/rings and actual machining.

Maybe i'll cancel the over bore and pistons and just get new rings and hone?

ideas?

and i used 2000 grit wet dry to sand the gasket residue off



Also, little side note. The previous owner apparently had it rebuilt at 250 or something. I dont have calipers to measure the diam. so i don't know what the bore is if it isn't stock. Also the head is back on and im driving it so i can't really take any better pictures and photobucket scales them down to the "Crap" resolution setting so you can't zoom in on the cylinders like i can on my comp.
augh im really in a jam about this over bore or hone buisness. I would save at least $300 if i just ringed and honed but then it's like ... but for only $300 more you could over bore and have new pistons! :O
aughhhh wugggg grr im writhing right now. I feel like im argueing with me self. I need some pursuasion to pay the extra dough
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on September 22, 2008, 06:45:07 pm
SOME PERSUASION! :D  :D
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel002-1.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 22, 2008, 06:49:49 pm
is that an over bore?
 :mrgreen:

do i have to do anything with the gasket if i get a 1mm over?
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on September 22, 2008, 10:04:44 pm
1.9 gasket is already larger.but the  1.6 gasket is openened up to accept the largest stock bore 77.48mm or something.Its only a mm.3rd bore.standard is 76.51mm(76.48mm piston)
                 first-76.76(76.73mmpiston)
                2nd77.01mm(76.98mmpiston)
                3rd/final77.51(77.48mmpiston)<my bore
I had to go final do to a bad ridge.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 23, 2008, 04:22:43 am
I gotchya. I'm going straight 1mm right off the bat. Did you do your own machine work?
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on September 23, 2008, 06:07:27 am
Nope ive got a shop that specializes in towmotor engines(idustrial engine).They are very similar to vw diesel.vw even makes an engine for Case towmotors.It was 300$ for eveything.magnaflux,bake/blast/bore/hone,straightness check.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on September 24, 2008, 09:04:05 pm
I'm thinking of getting a windage tray and cam baffle from Myke to add to the list

Also, anyone do anything like this...

summer driving and winter driving you swap suspension, tires and bumpers?

I have big euros on it now and for winter i want ot put the stock springs back on with the big tires i have and stock bumpers so i have massive ground clearance again
and just swap for the seasons.
im going to get 4x4ing lights too to wire up so i can just plug them in and bolt them to a roof rack i have
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on September 24, 2008, 09:40:02 pm
Go for it!
Personally I'm.shooting for coil overs so I can raise and lower as per season like you and I have a set of Saturn wheels with snow tires on them that I'll run as well. Leaving the bigs on though.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 04, 2008, 06:32:34 pm
OH the coillies are too low. I ahve them set as high as they can in the rear and it's still slammed. I could lower it at least 3 inches more if i had small enough rubber.
Title: My much anticipated 1.6td/aaz head.
Post by: ol'smokey95 on October 04, 2008, 08:06:38 pm
I'm looking at doing a bore on my AAZ  (1mm over on all 4) in the near future ; what brand name of pistons are the best ones to use? (Sorry if this is kinda high jacking the thread!? :lol: )
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 04, 2008, 08:11:18 pm
I was going to do a 1mm over on all 4 but i don't have the funds. I was just going to get histon heads from Prothe and use the stock rods because the stock rods i've read are rediculously strong. Can take 200hp apperently.

edit: thats on my 1.6td
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 15, 2008, 05:07:12 pm
After enormous deliberation i finally ordered my parts  :roll:
My final list is:

aaz head
7mm exhaust valves & guides
8mm intake valves & guides
re-using my lifters from the 1.6
the aaz cam
aaz HG

TDI ALH intake & gasket
the two garett T3 gaskets

ARP head studs

new standard size rings

EGT, oil temp, boost gauges. I need to find a temp gauge (i don't like the inaccuracy of the stock one)

Volvo intercooler

mercedez nozzles
Veggie seals in the pump

Gov mod and timing advance shim mod on the pump

I NEED TO STILL...make a spring compressor (Edit: CHECK!)
check that my water pump & oil pump are still OK (Edit: need water pump :( )
possibly rebuild my alternator if i start getting troubles (Edit: it looks ok!)
finish the tach converter chip to work for my gasser aftermarket tach (Edit: Proving extremely difficult...)
buy assembely lube and valve seating compound
and port & polish everyting.
Get the engine out &  Hone. (Edit: Engine still in there, no need for a hone)
wish me luck ...
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 15, 2008, 05:34:34 pm
Looks like you have a good idea on what your trying to accomplish!

Good luck but I don't think your going to need it.  :D
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 15, 2008, 05:36:18 pm
Well absolutely everything i know about diesels and VW's is from this site. I know some wrenching from courses i took but they don't really compare.




I still need the luck :P
but thanks i appreciate it. Holler at me if you see me over looking something or forgetting something because i will
I hope my intermediate shaft is okay too :(
common fix is a bearing change right?
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 15, 2008, 05:44:13 pm
Quote from: "Smokey Eddy"
Well absolutely everything i know about diesels and VW's is from this site. I know some wrenching from courses i took but they don't really compare.




I still need the luck :P
but thanks i appreciate it. Holler at me if you see me over looking something or forgetting something because i will
I hope my intermediate shaft is okay too :(
common fix is a bearing change right?


Usually the shaft is fine, the bearings are the issue.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 15, 2008, 06:52:53 pm
my block has 400,000kms on it and i dont know how much of that is on the rebuild i think it's had and who knows what's been changed on it. So ... I guess i'll just have to see. What should i be looking for? play in any axis for the main bearing? general Looseness? should there be "some"?
I uninsured it today  :cry:
hopefully yesterday wasn't it's last day on the road.


uhhh so i've been driving with the cam 180 degrees out
woops...or the flywheel 180 degrees out
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 24, 2008, 06:42:42 pm
I need help choosing paint.
Can anyone post pictures of paint they think looks good on an mk2 jetta?
Brands? suppliers?
I have an HVLP i can use and like 5 canisters so i can have several colours depending on how much the paint costs.
Please let me know!
I want to do two colours. Maybe an under tone or something.
Of if anyone knwos of a straight colour that looks good?
I can't do anything too fancy like metalic flakes because the body isn't in good enough shape to merit that kind of investment.
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on October 24, 2008, 07:56:43 pm
Tornado Rot all the way!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 24, 2008, 07:58:50 pm
I was thinking something less ... factory. Because i have the option to do so.

ok im thinking a glossy black!!! (but its still a stereo typical factory colour)

or should i do a professional flat black job to cover up my very poor roller job?
Flat black just stays rough and gets dirty very easily I'm not sure what to do
but it covers imperfections the best....

gah! i need help choosing! :P
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 27, 2008, 10:17:23 pm
Thanks for the tremendous input for paint, guys :roll: .

I have some stuff that maybe useful to someone at some point.
My lifters are smooth as glass!!! but they look strange. like these rings
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0215.jpg)
The spring compressor i had...
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0217.jpg)
Didn't work because the arms are different lengths  :evil:  :evil: (Yes, i cut my self the day before taking the head off)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0220.jpg)

I was tired of struggling with the keepers so i altered my LDA. Those screws did NOT want to come off.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0221.jpg)
So, i used the same method i used to get my brake calipers apart.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0223.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0224.jpg)


Smash it onto the head of the screw carefully as to avoid damaging the precious IP and out it comes!
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0227.jpg)

I have no CLUE why bosch used flat head screws for this? i much prefer torx  :D  :P (or what ever socket that is)


I asked a question about getting the shizz out of the thread holes for the studs/bolts and someone said to use compressed air ...  :roll: I let brake cleaner/lacquer thinner sit in there for an hour or so and then used "compressed air" to get it all out! (being very careful to block all coolant and oil holes.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0228.jpg)

This is my sad attempt at a spring compressor. Who doesn't like wood?  :wink:
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0229.jpg)
This is a tiny neodymium magnet from a screw driver. My intent was to grab the keepers out with it and press the valves down with a socket
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0231.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0232.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0233.jpg)

This didn't work, which wasn't surprising, but i was hoping someone could give me a tip or something? I'm trying to avoid grinding a socket, mostly because i don't have a grinder and filing would take forever (hack sawing would be very hard as well because im not sure how I'd clamp it. I don't have a vise.. only clamps... My garage is a wood shop and I've commandeered it to fix my veedub so please, bare with me :roll:
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 28, 2008, 01:39:11 pm
Try using a socket for a gasser O2 sensor. Already has the notch in the side.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 28, 2008, 01:40:13 pm
Quote from: "Smokey Eddy"
OH the coillies are too low. I have them set as high as they can in the rear and it's still slammed. I could lower it at least 3 inches more if i had small enough rubber.



I think you need to send the coil overs to me and I'll send you my KYB's and Neuspeed springs.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 28, 2008, 03:03:50 pm
I like my coilies!!!
you didn't comment on the turkey baster :( i was sure someone would...


I don't have a socket for an o2 sensor. Perhaps one of my friends does though ...
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 28, 2008, 04:19:39 pm
Quote from: "Smokey Eddy"

you didn't comment on the turkey baster :( i was sure someone would...



I thought about it but then decided I don't want to know.  :shock:
Title: My much anticipated 1.6td/aaz head.
Post by: saurkraut on October 28, 2008, 05:16:00 pm
I have turkey basters in my garage.

They're really handy to suck old brake fluid out of the brake reservoir befor using a pressure bleeder to bleed brakes.

(http://www.bmw-m.net/techdata/images/0702_007.jpg)


I bleed brakes atleast once a year on all my crap so I don't have to deal with blown out wheel cylinders and stuck calipers.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 28, 2008, 05:32:43 pm
i should really bleed mine. Never done it...
I think if i have a working car again that's first on the list.
Then paint  :D
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 29, 2008, 10:46:55 pm
Ok this whole "build" has taken like a year and im sure you've all seen it before many times im just terrified of breaking something so i like to post lots.

I solved my keeper issue by taking an old bicycle seat post and cut it like so...
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0237.jpg)
it's allum. so it wont damage the parts and its easy to make.
Its also a lovely fit. I was very pleased.
So pleased in fact that i took my injectors apart to fix that knockin i had and used a whole can of brake cleaner on them and a bit of 800 grit to clean them up... sorry about the blurriness. They're actually pretty shiny now.
there was one injector that was perfectly clean... anyone had that happen before? it was the hardest to get apart but perfectly clean on the inside.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0236.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 29, 2008, 10:52:48 pm
Quote from: "zukgod1"
Quote from: "Smokey Eddy"
OH the coillies are too low. I have them set as high as they can in the rear and it's still slammed. I could lower it at least 3 inches more if i had small enough rubber.



I think you need to send the coil overs to me and I'll send you my KYB's and Neuspeed springs.


The coil overs are crap. I paid 100$ for all of them.
they aren't "meant" for vw's so they are made for our cars at all. it's a rough ride with only the back in.
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on October 29, 2008, 11:11:25 pm
Quote from: "Smokey Eddy"
i should really bleed mine. Never done it...
I think if i have a working car again that's first on the list.
Then paint  :D


mfg recommends once every 2 years... should come standard with any brake work IMO... most of the population doesn't know this... i think its somewhere in the owners manual, but tucked away.  should be a safety concern, but most new fluids last way longer... and you can also get synthetic brake fluid that lasts twice as long.. so 4 year intervals.  depending on how handy you are, you might want to go this route.  twice as expensive, but lasts twice as long... how long do you want to keep the car?  :lol: bleeding brakes is a PITA IMO!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 29, 2008, 11:27:14 pm
I was taught how to in my mechanics course. Just need a friend to help now.
My master cylinder thing (that big black part) looks very new and shiny so i think the brakes were done just before i got the car. The fluid isn't a weird colour either.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 30, 2008, 10:29:16 pm
bah ok so im a little worried =( and disappointing.

Last time i had the head off (not long ago AT ALL) i cleaned up the cylinders with the pistons still in and there was no lip at all.
Now when i took the head off it was very sooty in there.
It's just grotty where the "lip" would be  i tried to clean off an area but its pretty caked on. how much lip is too much? I've asked this several times and i always get "if you can feel it with a finger nail"
but everyone's nails are different .... some of my fingers i cant catch it but on others i can.... and there are strange lines in one of the cylinders.
i can't feel anything but they're certainly there..
could possibly be from me trying to clean it a bit... but i dont know
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0239.jpg)
I hope that picture is clear enough to see

and i found
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0238.jpg)
which i already knew about but it wasn't completely torn like this ....
do i need a special tool to change out the cv joints?
Title: My much anticipated 1.6td/aaz head.
Post by: blkboostedtruck on October 30, 2008, 10:33:34 pm
yep a 12point ZXN 8mm
and a 30mm for the outside nut!
Duane

edit yes your cylinders need honed or bored i can see the groves even in those blurry pics.!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 30, 2008, 11:33:06 pm
Quote
yep a 12point ZXN 8mm
and a 30mm for the outside nut!



Dang. well i guess that's not going to happen....


I intend on honing
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on October 31, 2008, 10:20:05 am
be careful when your honing it's easy to go to far.

I'm not going to comment on the condition of your bore without a better pic.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 31, 2008, 06:39:29 pm
I do apologize, i'll take a better one with a real camera not my phone.
In the mean time, How do you measure the piston protrusion? I have feeler gauges... would that work?
anyone shout the three gasket sizes for the protrusion size?

my feeler's say 0.70 mm .... does this make sense?
that's for #1 at TDC (according to the flywheel)
Title: My much anticipated 1.6td/aaz head.
Post by: cyrus #1 on October 31, 2008, 07:02:52 pm
According to the Bentley:

Mechanical Engines:
- 1 notch - 0.67-0.80mm
- 2 notch - 0.81-0.90mm
- 3 notch - 0.91-1.02mm

Hydraulic Engines:
- 1 notch - 0.66-0.86mm
- 2 notch - 0.87-0.90mm
- 3 notch - 0.91-1.02mm


Edit: I own page 4 and it looks like you should be 1 notch.  :D
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 31, 2008, 07:04:47 pm
WOW.....
Oooooooooooooookay


uhhh so i've been using a 3 notch....

that explains a lot.... right?
if im meant to use a 1 notch and i've been using a 3....

and it barely starts....?

thanks cyrus


edit: jesus .... i can't believe that.
why was i so stupid and didn't make sure the prior owners had the right HG on it when it first started to have trouble starting...

I plan on running some extra boost (25 psi) arp's, metal hg, T3, big DP and exhaust. Should i go 2 notch then? or a 1 since its winter time around the corner? I want to drive it to the ski hills so it'll be cooooollllddd. a 1 notch would be good with less boost?
Suggestions? tips? I really don't know what im doing... clearly.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on October 31, 2008, 07:09:54 pm
You wouldnt have been able to tell unless you take the head off.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 31, 2008, 07:11:58 pm
i took the head off a year or two after driving it to "fix" the starting problem but i was like ...16/17 i was too dumb and uneducated to check the HG size i just figured... "well i'll get the same as this one here, (waving it in my hand) except a new one! that will fix it!"

DOH!


About the hone... I'm just going to clean it basically with the hone... get it as smooth as possible. Focus on the top as soon as the rest is smooth again. I don't intend on taking any steel off except to like bevel the "lip" at the top, if there even is one. It just feels dirty at the top.
Title: My much anticipated 1.6td/aaz head.
Post by: cyrus #1 on October 31, 2008, 07:41:31 pm
Holy smokes Ed!  I guess that's why most of the members on here recommend measuring your protrusion if have a 3 notch gasket.  Stupid lazy PO's.  :evil:
Title: My much anticipated 1.6td/aaz head.
Post by: burn_your_money on October 31, 2008, 08:17:41 pm
Get some bore gauges and measure the cylinders as outlined in the bentley. Most of the wear occurs at the top 20% of the cylinder (I think) so you don't want to focus your honing in that area. Unless your measurements tell you otherwise.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on October 31, 2008, 09:39:49 pm
Quote
Stupid lazy PO's

?? you mean Stupid Lazy Me?

Quote
Get some bore gauges and measure the cylinders as outlined in the bentley. Most of the wear occurs at the top 20% of the cylinder (I think) so you don't want to focus your honing in that area. Unless your measurements tell you otherwise.


Well i don't have those and i can't buy them so... i guess i'll just have to clean it up so i don't wreck the new rings....
I found an enormous amount of RTV in the oil pump filter mesh thing.
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 04, 2008, 01:25:40 pm
Quote from: "Smokey Eddy"


uhhh so i've been using a 3 notch....

that explains a lot.... right?
if im meant to use a 1 notch and i've been using a 3....

and it barely starts....?



Well, I don't think that should really affect starting.
For what I know, most tuned TD:s have been using a 3 notch gasket
and that's the rational choice anyway, considering the added boost and all..
just my 2 cents
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 04, 2008, 01:50:24 pm
I was thinking about that....

I thought the different sizse was purely FOR starting purposes. otherwise why would they make more than one size if it didn't matter which you used?
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 04, 2008, 01:52:39 pm
Well, it does affect the compression ratio, but in practice I understand it makes very little difference.
I think there are three gasket options purely to allow the exact right thickness, so that stock engines are all standardized even though the heads may differ.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 04, 2008, 02:35:24 pm
Oh, by the way i ended up using solvent + 600 grit to get all the soot off. I was very careful not to sand the cylinders down though ahahaha
I know it's very taboo but i got angry!!  :evil:  and it worked out ok.

Question!!!

I was able to push the pistons out the top with relative ease after i rubbed all the carbon off. There is a slight lip but if it is small enough that the rings passed over it no prob. isn't that a good sign? Or does it not really mean anything...
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 04, 2008, 03:55:50 pm
I think that's the way it should be. At least it was that way in my block which had been overhauled recently.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 05, 2008, 02:27:01 am
Woo hoo!
Okay! so i got that freakin water pump off!!!
The bolts that hold it on were FINGER TIGHT   :?

uhhhh

so i took it off anyways and found a crispy gasket of sorts that fell apart
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0249.jpg)

and the pump! with a nice looking impeller
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0248.jpg)

This came with the thermostat i got... any idea's what it's for?
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0250.jpg)

It's tempting to just get a new gasket and put that back on but no, i should get a new pump shouldn't i.

On the topic of vital pumps....
when should one change oil pumps? only when you get issues?
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on November 05, 2008, 06:16:52 am
Thats the gasket for the block to pump?I dont know what that extra flange is though.
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 05, 2008, 10:00:44 am
Oil pump can be measured for wear, a repair manual should have the guide measurements. Do also check the operating axle of the oil pump (along with the vacuum pump) - there's often play there, and in that case new parts are needed.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 05, 2008, 01:38:15 pm
Quote from: "TurboJ"
Oil pump can be measured for wear, a repair manual should have the guide measurements. Do also check the operating axle of the oil pump (along with the vacuum pump) - there's often play there, and in that case new parts are needed.


I can do those another time surely? when i have a little more cash flow.
Surprisingly enough everything seems really really solid on the bottom end. No play in anything i can get my hands on...

Is this what i want to change on the intermediate shaft?
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0247.jpg)
I read you hit it out with a socket from behind? Like the shaft seal on the injection pump? (that picture is turned 90 degrees for reference (dizziness) sake)
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 05, 2008, 02:24:33 pm
I didn't have to hit it with anything, I just pulled it out by hand. It wasn't tight at all.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 05, 2008, 02:29:11 pm
just undo those two bolts and the seal will slide out?
I'll have to try that this afternoon.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 05, 2008, 04:01:44 pm
It may be stuck to the block due to the gasket but ya it should just come off easily.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 05, 2008, 09:33:09 pm
wait wait wait
I'm not sure if we're talking about the same thing :P
Will the whole shaft come out if i undo those two bolts?
What should i pay for a new one?
(and i still don't know, is this the seal/bearing what ever that is a common replacement on the intermediate shaft??? or is it the other one closer to the gears that power the pump)
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 05, 2008, 09:49:34 pm
The shaft wont come out with the engine in the car.

That cap does hold it in but its not gonna fall out if you remove the cap to replace the seal and gasket.

What are you talking about "pay for new one"? The seal? $5. maybe.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 05, 2008, 10:29:54 pm
Thanks Dan.
I'm just weary of prices because Ebay always seems way too low and the vw/import shop in abbotsford seems very over priced compared to prices you guys give.
that's all...


I think I'm going to make a hilarious video of my build when im done and put it on youtube :P
complete with obvious "cock.....sucker!" bolts and victory dances of getting parts off like that blasted pulley. and then a finale of a wicked smoke tale wasting a gasser. If that ever happens...  :lol:  im  allowed to dream!!!
Title: My much anticipated 1.6td/aaz head.
Post by: VW_Commuter on November 05, 2008, 11:34:45 pm
I would consider picking up a complete engine gasket set.  That way you would have a gasket for anything that you might have to take off the engine without having to either pay for shipping and wait for each piece as you need it or having to run down to the autoparts store 5 or more times.
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on November 06, 2008, 12:05:41 am
Quote from: "VW_Commuter"
I would consider picking up a complete engine gasket set.  That way you would have a gasket for anything that you might have to take off the engine without having to either pay for shipping and wait for each piece as you need it or having to run down to the autoparts store 5 or more times.


amen... but the gasket kit i bought for my engine didn't come with the one behind the piece that smokey eddy is taking off.  i got it from the dealer for... get this... $10!!! "$10 for this skinny little piece of rubber" "yea i know..." at least the parts guy there was cool  :roll:  :lol:

the kit did come with what seemed to be an o-ring that might fit, but it definitely didn't!!!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 06, 2008, 03:05:10 pm
Hmph.
Maybe i won't bother taking it off...
Everything is just so phenomenally filthy all around there it makes me think it was leaking.... but i don't have significant oil loss. I never have to top it up but i end up changing oil every like 3,000 clicks though because i haven't done a big job up until now and it was just constantly having the coolant/oil drained.

I'm completely out of cash now after water pump and bearings and so forth. I can't really dabble with changing all the gaskets. I wish I could. I wish this was a real build. I wish someone would hire me ffs  :cry:  :roll: .

Right now I'm fussing about buying things like more solvent, RTV and anti-seize. I think i can make due with Simple green although i don't know what that stuff leaves behind ... i always prefer solvent.
Title: My much anticipated 1.6td/aaz head.
Post by: VW_Commuter on November 06, 2008, 04:07:44 pm
Quote from: "Smokey Eddy"
Everything is just so phenomenally filthy all around there it makes me think it was leaking.... but i don't have significant oil loss.


It only takes a little bit of oil and some driving around to make a mess on the engine.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 06, 2008, 04:28:56 pm
Yeah...
I guess a lot of that is belt bits too.

The Intermediate shaft has no play at all what so ever ... spining it clock wise to CCW it has a bit of a dead spot but i mean, that's expected with teeth on gears like that. I think its ok.

Just from turning it a little bit backwards  the pump sputtered oil out the filter end. I kinda wanna put the pick up line in some freshy and just try to run some through it to clean out that mesh. It's got silicone on it which is proving difficult.

I snapped one of the plastic pieces holding it together already so im not going to risk more.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 06, 2008, 04:49:32 pm
You can just un bolt the pickup tube from the oil pump so you can get it cleaned up really good.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 12:12:55 am
any recommendations AGAINST using a 1 notch AAZ HG with ARP studs and an AAZ head running 20-25 pounds boost?

My protrusion is 0.7mm. which is very close to rock bottom. (i think 0.65mm is the least? mine may even be that small. i used feeler gauges. 0.8mm was definitely too thick. That calls for a 1 notch HG.

I need it to start in -20c weather. maybe even -30. Got a season pass at an inland-ish ski hill and I can stay at my friend's cabin. I don't want to drive there and not be able to get back!!!


Thanks all,

Ed.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on November 07, 2008, 08:18:12 am
eddy ,did you measure all 4 pistons protrusion?
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 07, 2008, 08:24:19 am
I only know that none of the OE head gaskets are 0.7 mm thick, they're all less than that  :!:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 02:43:52 pm
Quote from: "dillenger1"
eddy ,did you measure all 4 pistons protrusion?


no i didn't =(
Do you think it will vary any significant amount though? they all "looked" the same... the piston i measured wasn't an anomaly by any standard
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 02:45:34 pm
Quote from: "TurboJ"
I only know that none of the OE head gaskets are 0.7 mm thick, they're all less than that  :!:



well the thickness of the HG isn't the same as the measure of piston protrusion is it?
someone posted a lovely table on my thread here on the previous page.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 02:46:16 pm
Quote from: "cyrus #1"
According to the Bentley:

Mechanical Engines:
- 1 notch - 0.67-0.80mm
- 2 notch - 0.81-0.90mm
- 3 notch - 0.91-1.02mm

Hydraulic Engines:
- 1 notch - 0.66-0.86mm
- 2 notch - 0.87-0.90mm
- 3 notch - 0.91-1.02mm


Edit: I own page 4 and it looks like you should be 1 notch.  :D


There is a massive range for the 1 notch. 0.20 mm range...
the 2 notch only allows for half that at 0.09 mm range
and as for the three, it has a 0.11 mm range.

my protrusion is 0.7mm, give or take 0.05mm, so a 2 notch would be greatly out of the range for that. Even with lots of boost i think i should still be using a 1 notch. (i didn't have very precise tools so my bottom end may as well be (for all i know) exactly 0.66mm protrusion.)
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 07, 2008, 02:56:37 pm
Yup 1 notcher is the one for you it sounds like.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 04:15:00 pm
I got a notice in the mail today saying my package from prothe is ready for pick up but the post office wants 100$ for me to pick it up???

I already paid 60$ to prothe to pay for shipping.
Where does this 100$ come from???

I don't have that money... what am i supposed to do  :?


Edit: moreover, where is this bill coming from?
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 07, 2008, 04:16:56 pm
Customs?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 04:18:25 pm
oh ...













 :cry:

Definitely the last time i buy anything from the states...
Lost 200+$ from the loonie drop
took 2 weeks to ship
huge friggen 100$ custom's fee...
I can't even pay to pick it up now im so broke...
pretty pathetic
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 07, 2008, 04:19:18 pm
Just guess. Is there a # you can call to see where/ what the charges are for?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 04:21:17 pm
The post office is just down the road. the card say's its not available till tomorrow after 1pm so i'll just go then...

You're right it must be customs but $90.51 ???? why is it SO much
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 07, 2008, 04:25:43 pm
I think they base it off what the shipper labels the packaged items as and the cost of said items maybe?
Every time I've ordered from/ shipped to Canada I've always labeled as "Core Return, auto parts" and never been charged extra.
Title: My much anticipated 1.6td/aaz head.
Post by: rallydiesel on November 07, 2008, 04:39:19 pm
He probably sent it UPS, which will hose you hardcore for brokerage fees. Always get stuff sent USPS unless there is no other way. Then go with DHL.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 04:43:25 pm
I just gave him the money and he sent it...?

Quote
Every time I've ordered from/ shipped to Canada I've always labeled as "Core Return, auto parts" and never been charged extra.


someone should really tell prothe that  :(
Title: My much anticipated 1.6td/aaz head.
Post by: vanbcguy on November 07, 2008, 04:47:34 pm
You have to pay PST & GST when things come across the border, even when it comes via Canada Post.  There's also a small handling fee that Canada Customs has started charging on things, but it's not much.  There's no duty on auto parts under NAFTA so "all" you pay is the sales tax.

What was your total price for the order?  I'm guessing around $1000?  That would make sense for $90+ in sales taxes in BC...
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 04:52:51 pm
650$ USD
it was shipped via "usps"

 :( I guess since the cdn doller dropped so much all the numbers are just massive
I think it ended up being 800$ canadian

and now the loonie is back up...
oh yay... just in time  :x


I think i just literally made the order in the worst possible month i could have.


so wait if im understanding this right.... I'm paying the tax twice?
or i paid your US taxes and now my own canadian taxes ....

again, im never buying anything internationally.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 05:02:32 pm
a bare aaz head
valves
tdi intake
egt, oil temp, boost gauges
tdi intake gasket
valve stem seals
aaz cam shaft
4 sets of rings
turbo gaskets
head gasket (DOH ITS A 3 NOTCH @$^@ :evil:  :evil:  :evil:  :x  :x  :x  :x  :x anyone need a metal three notch HG?)

cost me in excess $900.00...
did i even need the valve stem seals? I can't find the old ones on my old head. Are they stuck in there?
Title: My much anticipated 1.6td/aaz head.
Post by: vanbcguy on November 07, 2008, 05:09:30 pm
The "Core Return" thing will probably work, but it's technically not legal.  For someone like Prothe who is running a business doing this, he probably wouldn't want to risk getting arrested for customs fraud.  If I was sending/receiving something PERSONALLY I'd probably go that route though - you can always claim ignorance.  As a business he can't really afford not to declare things properly.

5% GST + 7% PST of $800 CDN would be $96 so it sounds about right...

Always always try and buy stuff locally first!  You definitely got hit bad on the CAD / USD conversion with this one...

There's a couple of Canadian auto parts retailers online that have decent prices and free shipping for orders over $75.  You don't have to pay PST when you buy things out of province (most of the sites are headquartered in Ontario) so it can often end up quite a bit cheaper once all the "fun" conversion factors are taken in to account.

I've shipped quite a bit of stuff to and from the US, there's definitely a lot of things you have to know about and unfortunately you found out the hard way on a really big order.  It's a lot easier when you get the "pain" on $60 worth of stuff rather than $800... Hey, for some things it's even worse - bikes for instance have nearly 30% tax added on when they come in to Canada!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 05:12:37 pm
Yeah thanks for the heads up.
Gotta learn somehow...

I looked at other dealers but their prices on parts was way more than i could afford and prothe's were affordable for me. Turns out i broke the bank anyways but oh well...
gotta learn somehow.
Hopefully I'll get a job today/tomorrow. *finger's crossed*
Title: My much anticipated 1.6td/aaz head.
Post by: theman53 on November 07, 2008, 06:47:34 pm
so somebody else has my kind of luck....
what if you gave the money to a relative or someone you trust to send it across? They could buy it here and then all you would have is shipping right?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 07, 2008, 07:10:56 pm
Don't know anyone in the states :(
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 08, 2008, 10:39:32 pm
Ugh...

So i picked up my parts from the post office, over joyed only to find a box missing the cam shaft i ordered and the turbo gaskets and 8 intake valves.

Kinda, very, really, choked about not having the parts i paid for.  :?
I hope he will ship it express... I can't really wait another 2 weeks with no car. Not super impressed but people make mistakes.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 10, 2008, 01:32:06 am
Fun picture update me excited time.
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04955.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04966.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04965.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04961.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04967.jpg)

those are my cylinders in order from left to right after i used a ball hone on them very lightly with some synthetic oil.
The one with the horrid scores is the one that had the broken ring  :(  I can't catch my nail on them but i can feel them with my fingers that aren't so rough (pinky).

i cleaned up all my valve stuff, they look new! sort of .... not really... but they're clean!!!  :P
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04956.jpg)
And stickers for Mark  8)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04958.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04957.jpg)

the tdi intake fits nicely on the aaz head with the bolts off the 1.6 intake. Anyone else use the TDI intake on the aaz? it sure makes for easy inter cooling. (EDIT: i had to modify this intake. Look at a later post on this thread)
(http://i49.photobucket.com/albums/f279/edmcclung/Car%20Stuff/DSC04969.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on November 10, 2008, 03:11:12 am
good stuff! some of the pics aren't showing though :(

Quote from: "Smokey Eddy"
Ugh...

So i picked up my parts from the post office, over joyed only to find a box missing the cam shaft i ordered and the turbo gaskets and 8 intake valves.

Kinda, very, really, choked about not having the parts i paid for.  :?
I hope he will ship it express... I can't really wait another 2 weeks with no car. Not super impressed but people make mistakes.


hmmm ya that sucks... i wonder why people ship things like that... i guess they want to ship whats in stock to you right away, but without the other parts it doesn't really matter, right? just more shipping charges...

and about the valve stem seals, its a very good idea to install new ones!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 10, 2008, 01:31:35 pm
OH no!! why aren't they showing!!! must fix that little issue!

I'm going to put new ones (stem seals) in the new head. my old valves literally fell out of the head. (Are they supposed to be very tight?)

I'm not sure why they ship like that? It's not so much a big deal anymore it got sorted out quite nicely 10 minutes ago.
i need a cam shaft from tyler though! He's being generous enough to sell me one for cheap (with a cam cover too!!!)
What a guy :D
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on November 10, 2008, 01:37:42 pm
I'm anxious to see how that head works for ya, Good I hope.

How does it look if you compair it with the old one as far as casting marks etc?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 10, 2008, 01:52:49 pm
Uhmmm
its a little rough... some shavings have fallen out of it so i shook it around to make sure there were no more.

Its rough in places yeah but all the machining is fine. If i really cared i could smooth it all out when i port&polish.

I just might.
As for the coolant passages ... it's not like rediculous. looks like normal forms that haven't been filed/sanded or anything.
Title: My much anticipated 1.6td/aaz head.
Post by: zaprzal on November 10, 2008, 01:59:20 pm
Quote from: "Smokey Eddy"
Anyone else use the TDI intake on the aaz?


1.9 TDI PD 130 and 150 intake manifold is nice. I would use it.....but I have 1.6d head  :?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 10, 2008, 02:03:00 pm
Which do I have?
130?
Title: My much anticipated 1.6td/aaz head.
Post by: zaprzal on November 10, 2008, 05:14:48 pm
Quote from: "Smokey Eddy"
Which do I have?
130?


tdi PD look like this:
http://img368.imageshack.us/img368/3121/kolektorawxkm7.jpg
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 11, 2008, 12:29:51 am
Hmmm Interesting.

I still don't know what i have? :P
prothe's site called it a TDI intake...
is it an early tdi? like pre 2000 or something



Sigh, delayed another three weeks. Oh well, at least it'll all be right by then.
I got an oil temp gauge. Where should i put the sender?
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on November 11, 2008, 01:01:43 pm
Quote from: "Smokey Eddy"
Which do I have?
130?


I think the 90 hp TDI at least has a manifold like the one in your picture. I had one with engine code ALH on a Skoda Octavia.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 14, 2008, 07:46:43 pm
Quote from: "zukgod1"
The shaft wont come out with the engine in the car.

That cap does hold it in but its not gonna fall out if you remove the cap to replace the seal and gasket.

What are you talking about "pay for new one"? The seal? $5. maybe.


I just got back from wakefield sperling...

they want over 25$ for one intermediate shaft seal. I said immediately screw that.
That would have made my parts consisting of:
a HG, rod bearings, intermediate shaft seal and timing belt $150.00... :?

Which is rediculous. I'm not paying that.
I'm going to pay 50$ for the head gasket and probably re-use the rod bearings. and the timing belt was 40+ dollars... i remember paying 22$ for my last one which still looks fine... i may just keep using it and get a new one when i have more money.

Where on earth do you guys get parts for so freakin cheap???
Title: My much anticipated 1.6td/aaz head.
Post by: rallydiesel on November 14, 2008, 08:01:57 pm
I get my stock replacement stuff from:

http://www.importcarpartscanada.ca/index.wws

Shipping's fast and prices are good. Plus they tell you the manufacturer before you order  :wink: .
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 14, 2008, 08:13:04 pm
This site asks $53 for what the what the, i thought, "cheap" parts store is asking over $120 for.

but they don't have some items i'd want.
They only have a 2 hole aaz head gasket. I'd want a 1 hole :(


what is the difference between "web only" price and "list price" ???
Title: My much anticipated 1.6td/aaz head.
Post by: rallydiesel on November 14, 2008, 08:23:19 pm
The web only price is what they charge. The list price is just a marketing thing but it's probably not far off what a dealership would charge.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on November 14, 2008, 11:35:26 pm
Quote from: "rallydiesel"
I get my stock replacement stuff from:

http://www.importcarpartscanada.ca/index.wws

Shipping's fast and prices are good. Plus they tell you the manufacturer before you order  :wink: .



I used that site  :D  :D  :D  :D  :D  :D  :D  :D
got LOTS of extra stuff and it was still under $120
Gosh Wakefield is gonna be sad when i tell em i got a way way way way better price.

That place in the link is in Alberta!!  Half the freakin' tax. That's so awesome. And like 2 days to ship to my house for free. What a score. That site is going to be re-visited im sure.

I had to settle for a 2 notch HG though. They didn't have a 1 notch metal one. The difference is so minute i really don't think it will be a big deal. It will help a little i guess with the added boost.

Edit: im retarded, it's ontario.
Title: Update
Post by: Smokey Eddy on December 05, 2008, 06:59:34 pm
Update time. Yay pictures
Drilled and tapped that cock sucker last night!
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0300-1.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0299.jpg)
Plugged my waste gate
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0304.jpg)
Got my guages in
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0292.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0303.jpg)
New White dash LED set up
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0302.jpg)
My new lead terminals. I replaced the pre-existing ground with a huge one and moved the old ground to ground to the body. I hope it will crank faster now :P
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0311.jpg)
My two huge out put V6 Taurus fans. I'm currenty drawing up a template for a shroud and frame for the fans. I'm also going to modify the front end to fit my intercooler aswell.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0310.jpg)
And last but certainly not least, my ported, gasket matched, ALH intake ready to pwn. Notice the BOV delete ;) I reccomend this swap for an AAZ head.  I had to modify the elbow though. I put a silicone elbow on it that you can swivle for any intercooling possitioning you want. It's totally versitile. I added a lip too for a better seal.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0308.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0309.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on December 26, 2008, 05:57:04 am
Finally got the right valves and threw it together!
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7241.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7242.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7245.jpg)
I made this sort of magnetic V block for drilling the block's steam holes while it's in the car.
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7250.jpg)

Coming along nicely now!
Just need to do exhaust, rad/intercooler mount, fans and plumbing after i get the ring set.
Title: My much anticipated 1.6td/aaz head.
Post by: spencebm on December 26, 2008, 10:36:11 am
how hard was it to slap that egt gauge in there?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on December 26, 2008, 05:16:47 pm
Oh, not at all. The bits tend to catch the cast and complain a bit but if you have good quality bits they shouldn't break. Use lots of oil.
I put the mani in a vice and it was easy! The threads for the sender mount is tapered so you just have to choose the right thread pitch and stuff. start small because you can always drill out the next size up.
Title: Valve spring compressor
Post by: Rabbit TD on December 26, 2008, 09:45:58 pm
Smokey, are you talking about cutting a groove in a deep welll socket for getting to the valve keepers.  I found that my oxygen sensor socket fit right in the bore and used a plain old $25 valve spring compressor to push it down, and you can get to the keepers easily, couldn't have worked any better' :)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on December 26, 2008, 10:26:50 pm
That's refering to a very old post?
I made this out of a bicycle seat post.
I later ground the opening wider.
Combo that with a normal wood working clamp and a table and it works fine with needle nose pliers.
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7285.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/IMG_7284.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on December 28, 2008, 05:01:24 am
Are those pictures too big? do they take forever to load?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 02, 2009, 03:56:15 pm
Finally!
Here are the bolts i put on the LDA. I think anyone doing any work on their IDI should change those stupid slotted bolts our for real ones.
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05031.jpg)
You can see the ALH intake, NEW HEAD! :D, and continental timing belt here! neat stuff. Finally moving forward.
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05029.jpg)

Still need to add a nipple in the boost side of the turbo closest to the intake for the LDA and gauge to get pressure from.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 02, 2009, 04:06:19 pm
Here's the cam cover Burn Your Money (Tyler) sent me. It didn't look like this when i recieved it :P but it looks good now!
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05032.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05033.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: hamradio on January 02, 2009, 08:00:12 pm
Is that a rubber line clamped to a metal one, or a rubber line clamped to the the old once rubber line?


(http://i49.photobucket.com/albums/f279/edmcclung/DSC05029.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: cyrus #1 on January 02, 2009, 08:02:18 pm
Nicely done Ed!  How much longer until she roars to life?  :twisted:
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on January 02, 2009, 09:32:44 pm
looking good Ed! glad you finally got your parts! 8)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 03, 2009, 03:32:40 am
Quote from: "cyrus #1"
Nicely done Ed!  How much longer until she roars to life?  :twisted:


I Certainly HOPE it roars! im planning on big exhaust.
to answer your question it depends on when i can make a downpipe...
I have to use my friends welder and he's seeing his ex again which means he never wants to hang out  :roll:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 03, 2009, 03:32:59 am
Quote from: "53 willys"
looking good Ed! glad you finally got your parts! 8)

got em and didn't break em this time!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 03, 2009, 03:35:05 am
Quote from: "hamradio"
Is that a rubber line clamped to a metal one, or a rubber line clamped to the the old once rubber line?



Sorry, what are you refering to?

If you're talking about that line that goes over the top of the head it's just the cold start cable moved out of the way....
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 03, 2009, 08:41:20 am
Quote from: "Smokey Eddy"
Quote from: "hamradio"
Is that a rubber line clamped to a metal one, or a rubber line clamped to the the old once rubber line?



Sorry, what are you refering to?

If you're talking about that line that goes over the top of the head it's just the cold start cable moved out of the way....

Hes talking about the fuel line.
Title: My much anticipated 1.6td/aaz head.
Post by: theman53 on January 03, 2009, 08:45:36 am
*quote*And last but certainly not least, my ported, gasket matched, ALH intake ready to pwn. Notice the BOV delete  I reccomend this swap for an AAZ head. I had to modify the elbow though. I put a silicone elbow on it that you can swivle for any intercooling possitioning you want. It's totally versitile. I added a lip too for a better seal.
*end quote*
What did you do to accomplish this. This is a different intake than mine and just wondering what you did to delete the BOV.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 03, 2009, 10:52:28 am
Too cool Ed!

Not even my car and I'm really looking forward to hearing you say "its alive!"

Good job man, glad you have stuck with it.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 03, 2009, 03:16:17 pm
Quote from: "theman53"
*quote*And last but certainly not least, my ported, gasket matched, ALH intake ready to pwn. Notice the BOV delete  I reccomend this swap for an AAZ head. I had to modify the elbow though. I put a silicone elbow on it that you can swivle for any intercooling possitioning you want. It's totally versitile. I added a lip too for a better seal.
*end quote*
What did you do to accomplish this. This is a different intake than mine and just wondering what you did to delete the BOV.


I bought an ALH intake and cut the top piece off with a hack saw, then i smoothed it all out with a dremel tool.

You have to cut a couple other little nobs off that aren't nessisary (that are used on the ALH engine) I might have a picture im just looking Hmm i don't I'll use prothe's
(http://www.volkswaparts.com/images/038129713K.JPG)
(http://www.volkswaparts.com/images/038129713KPic2.JPG)

I hope that makes sense. So you have to cut off that support arm and then cut the top off (or else it conflicts with the turbo outlet). I just put the silicon elbow that my 1.6 intake already had on there. It is astonishingly bigger than the 1.6td. And if you look at that intake with a 1.6td intake beside it you'll notice something very obvious :P (there is no BOV hole), that's why i chose this intake.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 03, 2009, 03:19:44 pm
Quote from: "dillenger1"
Quote from: "Smokey Eddy"
Quote from: "hamradio"
Is that a rubber line clamped to a metal one, or a rubber line clamped to the the old once rubber line?



Sorry, what are you refering to?

If you're talking about that line that goes over the top of the head it's just the cold start cable moved out of the way....

Hes talking about the fuel line.


It is a clear (orange tint?) line clamped into a rubber line so I can see if there are bubbles coming from the fuel filter.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 08, 2009, 07:19:42 pm
well here is it... the first start up.
No turbo, no lda.
I only ran it until it would idle on it's own but the sound frightened me so much that i shut it off before it got hot. Started so fast though!!!  :shock: Totally alien experience for me...

I don't know what i should expect the exhaust to sound like coming straight out of the down pipe like that but it was a loud popping sound... like a beefy tractor or something... very beefy sound. The video even in the quality i recorded it in filters out the scary sound. It was LOUD.... and it was idling rough... I gave it a bit of gas and it sounded so frighting i dare not do it again!
Lots of black smoke too because of no turbo boost im guessing?

What does seating rings sound like? what does new valves sound like? what does exhaust straight out of the down pipe sound like?

I really want to run it, till it's hot and then re-torque but im scared i was ruining it. It sounded very uniform, no odd out bursts...
but man was it ever loud... idle im guessing was at about 800-900rpm (my tach isn't done yet)

Needed some help from a full battery
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05038.jpg)
The idle...
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05040.jpg)
Gave it some pedal (very little)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05041.jpg)

the video. I apologize if it's really loud. You may want to turn your speakers down?
(http://i49.photobucket.com/albums/f279/edmcclung/th_MOV05044.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=MOV05044.flv)

Does that look normal? im a total noob with this stuff as i hope (if you're reading this, this is true;) you already know that.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 08, 2009, 07:34:22 pm
It sounds fine eddy.With no turbo it will be loud as hell.Ive got a 2 1/2"straight pipe and its not that loud.The turbo is a great muffler.I mean, just imagine being next to small grenades going off.thats pretty much what you have.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 08, 2009, 07:35:20 pm
well the turbo is there! it's just not connected to the intake...
your re-assurance just slowed my heart rate by about 40bpm

Is it the cetane booster that is making the white or really bad nozzles or is that normal too?
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 08, 2009, 07:47:37 pm
the white smoke is the rings not set yet as well as you needing more advance.dont let it idle for long,warm up is ok,but you wanna be able to seat the rings(full load)If you glaze the walls it will just take longer. it sounds ok still without a downpipe i guess.like you said no irregular noises.You need to advance it.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 08, 2009, 08:24:57 pm
Mmm okay. Thanks for the advice.
So advance would be to push the pump towards the head, right?
I didn't expect it to be proper because i loosened all the bolts off of everything get as much off as i could. I just went nuts cleaning stuff while i was waiting for parts.
Dave, from passenger, said he'd do my pump timing with me on a sat. for a 12 case of sleeman's honey brown :roll:  :lol:
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on January 08, 2009, 08:47:56 pm
that doesn't seem too bad... what temp did you start it at? did you have the block heater plugged in???
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 08, 2009, 08:48:10 pm
correct.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 09, 2009, 01:18:51 am
it was a little cold. I had the block heater plugged in prior to it being rolled onto the drive way. I have it plugged in all the time now. it was between 4-8 celcius.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 11, 2009, 03:47:04 am
Woo Hoo!!!
should my turbo sound like this?
(http://i49.photobucket.com/albums/f279/edmcclung/th_MOV05053.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=MOV05053.flv)
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 11, 2009, 10:04:16 am
Your idle sounds a little high.the turbo sounds good.You do have a stumble though.Are all your injectors tested?Is that a cold engine?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 11, 2009, 03:46:30 pm
Yeah the idle is high i know. I have to bring the idle back and the fuel screw in.

The timing is very very very retarded, could that be the stumble? So retarded that with the cold start IN the engine will stall even when hot.

It wasn't cold per say. It took a long time for the fan to turn on but it did eventually. That vid was taken probably  20 minutes of idleing before the fan came on.


Which raises a question ...
I'm going to post a picture of the temp gauge followed by what my oil temp gauge says.
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05048.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05046.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05059.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05049.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05060.jpg)


That oil temp seemed really high to me considering how low the temp gauge reads....

the oil temp stayed around 210 and the temp gauge got to the middle, then water temp went way down (the thermostat opened) then never got back to the middle and then the fan came on but the temp gauge didn't read in the middle at all. It was about half way between the solid white and the middle mark.

I'm using probably 80% water to 20% coolant which i know is wrong but i just wanted to get it hot and retorque. I'm going to drain it all now and replace it with 50/50.

Can anyone comment on the oil temp?

The injectors were tested with merc nozzles and we OK. I listened to each injector with a screw driver and they all sounded quite nice. some slightly different tones but no notable clacking or anything.
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on January 11, 2009, 06:23:12 pm
what oil are you running in the motor?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 11, 2009, 06:29:37 pm
15w40 conventional for break in purposes only...
I'm switching to synthetic after probably 2-3 thousand kms or when i can tell that the rings have seated.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 11, 2009, 08:23:58 pm
did you retorque your head bolts?It will take your rings longer to seat with all the idling.
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on January 11, 2009, 08:24:15 pm
I would think something is up with your water temp sender?? was the tstat open??



dont forget...water cools an engine better then coolant(glycol) coolant is only there for lube/anti-rust and antifreeze...
but if it never froze straight water or dang near straight would be best.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 12, 2009, 12:40:40 am
Quote
did you retorque your head bolts?It will take your rings longer to seat with all the idling.


Yes, i retorqued. I know that idling makes the seating take longer but i wanted to get the retorque over with. I didn't anticipate taking so long to heat up.


Quote
I would think something is up with your water temp sender?? was the tstat open??


I bought a new sender but which connector sends the info to the dash? the brown/orange one or the blue one?
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05030.jpg)

I am talking about the connectors that go on the flange that sends coolant from the rad to the head and goes down to the pump. I asked this question a while ago but i didn't really get a straight forward answer... I know one of them is to turn the glow plugs off, and the other?
If anyone knows what colour wire does what that would be great.

The top hose was cold, then went hot so the tstat did open.


Edit: I just read that the gauge lead is the yellow with red stripe (what i would call the orange one)

I guess what im really asking is, has anyone had to fix or replace the gauge in the gauge cluster?
Title: My much anticipated 1.6td/aaz head.
Post by: lord_verminaard on January 12, 2009, 10:04:24 am
Are you sure you don't have your oil temp gauge hooked up to a coolant sensor?  There is almost no possible way your oil temp could get that high by idling.  When I drove my gasser Scirocco 250 miles on the highway last summer, it was 85 degrees out, I was going 75 mph, (4000 rpms) and the oil temp didn't get any higher than 85C (185 F).

Edit: Usually the senders for the gauge in the cluster are 1-pin deals, like this:
(http://www.sjmautotechnik.com/trouble_shooting/ecupic/ECT.jpg)

I'm not sure when VW stopped using this type of sender.  On my Scirocco, the oil temp and coolant temp for the factory gauges both use this sender. (2 of them in different places)

Don't know if that helps or not.

Brendan
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 12, 2009, 04:18:09 pm
Yes I am sure  :(
I have it replacing the pressure one that goes right above the oil filter.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0271.jpg)
The brass one is the sender that came with the gauge...
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX0270.jpg)


The oil temp never went higher than this
(http://i49.photobucket.com/albums/f279/edmcclung/DSC05059.jpg)

could it be that the sender is too long and it's blocking flow?
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 12, 2009, 04:29:19 pm
What are you getting for oil pressure?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 12, 2009, 04:30:11 pm
double post
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 12, 2009, 04:31:13 pm
i don't know :oops:
I don't have a pressure sender and gauge. The oil is getting to the top of the engine though, that's for sure. I tried to use my rubber 1.6td valve cover gasket and oil leaked out like crazy.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 12, 2009, 04:37:17 pm
that sucks.. Oil leaks are not fun.

I would tend to think the oil gauge is not reading correctly.
do you have another temp gauge of any kind laying around?

You could swap out the gauge really quick to see if that's the case using the current sending unit.

If it reads high as well try another sender to make sure you have eliminated the gauge being an issue.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 12, 2009, 04:38:29 pm
Quote from: "zukgod1"
that sucks.. Oil leaks are not fun.

I would tend to think the oil gauge is not reading correctly.
do you have another temp gauge of any kind laying around?

You could swap out the gauge really quick to see if that's the case using the current sending unit.

If it reads high as well try another sender to make sure you have eliminated the gauge being an issue.



I don't :(

dang it... now im worried

could i use the sender that i took out of that location? or the sender in the right side of the head? (looking at the front of the car)

(ps. the oil was brand new and everything was super clean so it wiped off no prob. I got the right gasket today.)
Title: My much anticipated 1.6td/aaz head.
Post by: regcheeseman on January 13, 2009, 07:30:34 am
Quote
I asked this question a while ago but i didn't really get a straight forward answer... I know one of them is to turn the glow plugs off, and the other?
If anyone knows what colour wire does what that would be great


Blue/white - is the glow plug sender (I have this disconnected on every TD VW i've ever owned - and recommend it everyone who struggles with hot starts)

Yellow/red - is the temp guage sender.

Same on Mk2 and Mk3 although the two senders have been replaced with one with four terminals
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 13, 2009, 03:59:27 pm
Quote from: "regcheeseman"
Blue/white - is the glow plug sender (I have this disconnected on every TD VW i've ever owned - and recommend it everyone who struggles with hot starts)



ahh! i was having a terrible time with hot starts!
Thanks budd!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 13, 2009, 05:29:04 pm
OK!

SO that oil temp sender was blocking the flow and triggering a low pressure switch which didn't go off until i got the RPM up a bit, then it would stay on buzzing in the dash.
I re-located it to the top of the head.
I still get pretty high oil temp readings... it idles at around 210F and driving goes down to 185. When really givin'er it will get to 220 MAX but that's still much too close to 250 for my liking.

If anyone has ever driven with an upside down downpipe and no hood and a T3 with no BOV or waste gate.... i can't express how loud the turbo is... it's like... .... i really can't explain it. My ears are ringing.

It really likes to tear up the tires in 1st, no clutch cheating req. :twisted: . It sounds a LOT like a semi-truck with just normal driving but when I floor the pedal it's like nothing else....
Black plume of smoke for a second, then i can see the heat waves of the exhaust, the EGT gauge only JUST registers 600F and it launches with the scream of the turbo...
If anyone is having issues with spool time on their T3, don't have ANY exhaust! 8)

I'm shaky i can't believe how different it is to drive now.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 13, 2009, 05:34:28 pm
Quote from: "Smokey Eddy"

 the EGT gauge only JUST registers 600F and it launches with the scream of the turbo...


I'm glad to hear it's moving under it's own power Ed thats great.!

600 deg?is that the max reading?
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on January 13, 2009, 06:11:11 pm
looks like you have a very successful 1.6/1.9 frankenmotor there!  a while back chrissev (no longer with us) went to a 1.9 head on his 1.6, and ran into a bunch of problems... most being cold starting :(
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 13, 2009, 06:25:32 pm
Dan, 600F is where the gauge starts to read.
It starts (with the block heater) instantly... very impressed with my self :D

It starts with and without the GP's on.
without the GP's on it just puffs twice white before it starts.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 13, 2009, 10:08:03 pm
oh min of 600 deg, i get it!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 14, 2009, 02:54:52 am
i was more aggresive :twisted:  today with it (my friend was there so you know) just going up and down my street making some smoke.
 :twisted:  :twisted:  :twisted:  :twisted:
i saw the EGT gauge move a LIL bit when the turbo was screaming and it was at probably half pedal in 2nd gear :P
borderline doing a burn out with my 195/65/r15s... my old engine couldn't light them up in first even with the clutch dumped. It's weird how big of a difference a bigger head and intake is. All ported and polished...(oh yeah and no BOV or waste gate)
It could do the old smaller stock size tires in the rain, up hill, but not in 2nd gear - no way.
I'm very confident that with slightly more fueling this hybrid design can really light up tires (especially low profile tires) in second gear.


Just have to get it properly timed and maybe some new injectors (at least nozzles anyways) are in order. eventually. oh yeah and the intercooler.
and maybe water/meth injection.
At what point do you have to start worrying about damaging rods and or piston heads?
Just today i felt like i was being really rough on it but maybe that's just because the "exhaust" is just an upside down downpipe...
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 14, 2009, 10:56:37 am
You need to keep it under 10psi for the brake in, the best would be below 5psi.

If you go higher then that your actually distorting the rings, they wont seat properly.

I'm basing this off what Total Seal told me. I don't see how it would be any different with standard rings.

It's good to load/ unload them several times but under normal driving. the turbo will add the "extra" as if you were pushing it harder in a gas situation so no need to rail on it.

Be nice as in not rough for the first 500 miles then a bit more aggressive up to 1000 miles then drive as usual.

Now don't take the "Nice" comment as drive it like a grandpa, just keep the boost down. Your going to be pissed if you have to tear it down in 15k because the rings are toast.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 14, 2009, 04:22:32 pm
Yeah i would be pissed....

Thanks Dan.

Frick i misplaced the T to split the LDA line for a boost gauge. I made one out of brass fittings but it's being used to keep my injectors in line (because i broke two fuel return nipples)
Guess i'll just make another or something. I haven't seen the plastic T's for the rubber lines anywhere, only in the box my gauge came in.
I think my parents threw it out. :roll:
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on January 14, 2009, 04:31:13 pm
Man you parents haven't been very supportive on this project have they?

I'm glad you have it running now. Better get your hood back on before they toss it.  :shock:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 14, 2009, 04:34:53 pm
No not really...
I wanted to show my Pops how fast it starts (because that was the reason they wanted to turf it before) and that's when it made all the white unburnt exhaust (coz of the rings) and he wasn't very impressed... :(
No amount of explaining works either. They think it's always me trying to change the truth to keep this "useless" car that for some reason i have some infatuation with.

When it was running hot and i was changing the pump timing on Sunday  (he was home from work) and revving it a bit he could hear it inside and said it sounded good...? if that's a plus
oh well. Almost done now. Just gotta go on a road trip or something to seat the rings.
And make that flippin down pipe and exhaust :evil: Anyone in abbotsford care to help a welder-less dubber make a downpipe and straight pipe exhaust? :P
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 14, 2009, 07:26:25 pm
come on down to chardon ohio and we'll weld ya one up!
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on January 14, 2009, 09:55:25 pm
right on ed!! glad your up and running for the most part...it's gonna take some time to iron out the bugs and kinks...but as you can tell all ready it's worth the end result!
cheers 8)
Title: My much anticipated 1.6td/aaz head.
Post by: theman53 on January 14, 2009, 10:17:26 pm
Could I come UP to chardon OH  :lol:  
If I get some time how funny would it be to roar for 1.4 hours to chardon with nothing but a downpipe...It might be worse from CA though.
Great work Eddy I hope when spring comes mine goes as well as yours
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 14, 2009, 10:25:57 pm
Quote from: "theman53"
Could I come UP to chardon OH  :lol:  
If I get some time how funny would it be to roar for 1.4 hours to chardon with nothing but a downpipe...It might be worse from CA though.
Great work Eddy I hope when spring comes mine goes as well as yours


I hope yours goes well too! but takes about 1/5th as long as mine did.

I reccomend getting at least 1 extra ring set incase you break a ring.
Making that thing i used to get the keepers out of the head if you dont have a tool already.

uhhmm what else... don't be afraid of drilling the block holes, the iron is super super soft. just make sure it lines up with your HG.

What else... OH and the ALH intake works really well if you have a dremel tool with a cutting disk on it to mod it up a bit.


Ha! I'd love to home to OH to see you guys but i wouldn't get through the border im sure!!!

Sir, why is your hood on the roof?
Uhhhh... it's a spare...
A spare? your car has no hood right now and... is that the exhaust?
uhhhhh...........No! its part of my really expensive ... flo master system... for ... extra clean emissions!
not to mention chardon ohio is only what... 4,000 some odd km away.


I just realized im actually really stuck right now with no down pipe...
the stock one doesn't really fit properly. It vibrates the exhaust against the underside of the car.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 16, 2009, 08:54:03 am
come up with a way to breakup your welding buddy and his girlfriend 8) I know i saw her with duane the other night! :wink:  :wink:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 16, 2009, 09:06:45 pm
With Duane! that sneaky bastard!
Definitely screen shotting THIS!
We yanked the old exhaust off last night. It was fun.
I like BFH's (big fu**ing hammer) they get the job done RIGHT!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 17, 2009, 05:13:11 pm
"British Columbia - No film is permitted on the driver’s compartment, right and left. Any film may be installed on the side windows behind the driver. Any film may be applied to the rear window, provided the vehicle has 2 exterior rear view mirrors. "

 :cry:
Title: My much anticipated 1.6td/aaz head.
Post by: blkboostedtruck on January 17, 2009, 05:19:53 pm
Quote from: "Smokey Eddy"
With Duane! that sneaky bastard!
Definitely screen shotting THIS!


sneaky bastard? :shock:  what did i do right? or this has no reference to me
and are talking about somebody else? catch me up here! i wasn't listening!  :?
Duane
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on January 17, 2009, 05:48:25 pm
Quote from: "blkboostedtruck"
Quote from: "Smokey Eddy"
With Duane! that sneaky bastard!
Definitely screen shotting THIS!


sneaky bastard? :shock:  what did i do right? or this has no reference to me
and are talking about somebody else? catch me up here! i wasn't listening!  :?
Duane


if you can't remember, then you obviously get too much action!!  :lol:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 17, 2009, 05:57:06 pm
It's just a joke Duane  :P  :roll:
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on January 17, 2009, 06:02:52 pm
duane, you were sleeping with eddys welding buddys girlfriend?you dog.
Title: My much anticipated 1.6td/aaz head.
Post by: blkboostedtruck on January 17, 2009, 06:13:25 pm
no harm done! :D  i don't mind being the center of the punch line! anybody have a pic. of her?naked pic or her my trigger my memory? and don't post a pic of a fat one! i might not have any morals! but i do have standards!!  :roll:  remember i lived through the 70's and fried some brain cells back then!
Duane
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 17, 2009, 06:14:43 pm
Quote from: "blkboostedtruck"
no harm done! :D  i don't mind being the center of the punch line! anybody have a pic. of her?naked pic or her my trigger my memory? and don't post a pic of a fat one! i might not have any morals! but i do have standards!!  :roll:  remember i lived through the 70's and fried some brain cells back then!
Duane


BAH hahahahahhahahaha!!!!
Should i be ashamed that this is my thread?
Title: My much anticipated 1.6td/aaz head.
Post by: blkboostedtruck on January 17, 2009, 06:34:09 pm
if nobody post a pic of her i'm just gonne go back and delete my post and clean up my off topic stuff in eddy's thread
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 17, 2009, 06:47:05 pm
what ever i don't care honestly
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 30, 2009, 11:48:27 pm
HOLY EFF

I just  drove her up and down my street this time WITH the turbo connected up. SWEET JESUS.

hit 20psi by sort of accidentally on purpose by accident and blew the rubber line to my boost gauge out of the intake!!!!

the change from 10psi to 20psi is just NUTS. Why does no one else stress this more?  :P

it starts INSTANTLY... It sounds totally different... It makes a deep bogging sound under load at WOT accompanied by a screaming sound (turbo) SO i've been told.

I didn't drive it like crazy, the fuel screw is still pretty far out but holy EFF it's a different car.
I finally got the car i bought back in oct/nov today.
I'm still shaking. It's not what i expected at all. and it's not intercooled yet...
it really likes to break the tires loose in 2nd on the gravel when it starts to boost. If i'm on a bare patch it just LAUNCHES. Definately raceable to my parents TDI now ...
phew what a ride...


on a more technical note there was some oil in the intake when i took the hose off to make the boost hose  fit better. The exhaust smells oily and LOOKS oily but im guessing that is just because the rings need to seat.
and it makes a really deep mean noise when letting off the pedal after boosting, not alarming just ... loud and really deep sort of a    WAAAAAUUUUUUUuuuuuuuuuuuuuuu
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on January 30, 2009, 11:55:11 pm
Congradulations Eddy it's a bouncy baby turbo diesel!!!

Nothin' like diesel torque *and* that feeling when the boost kicks in, huh.  And there's something about figuring that you built the sucker from the ground up with your bare hands.

 :lol:  :lol:  :lol:

Whenever I get the urge and my foot "accidentally" calls for boost I get this big grin and my wife just looks over at me and shakes her head.... "not in front of the children you fool". :wink:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 30, 2009, 11:56:09 pm
hah! did you get my pm?
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on January 31, 2009, 12:09:42 am
Whoops... forgot about your PM... you got one back.
Title: My much anticipated 1.6td/aaz head.
Post by: cyrus #1 on January 31, 2009, 12:22:54 am
Congrats Eddy!  What else do you have to do on it?  I'm glad you saw this through.  8)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 31, 2009, 12:24:14 am
adjust the downpipe and weld up some 2.5 both sides exit exhaust ;)

then make my shroud for the taurus fans and slide the intercooler in there. but that's not for a little while. I think i need a job before i do that to pay for stuff im going to break.

Edit: and clean the garage...
while Mika was outside i laid down some solvent to clean up the garage floor.

oh and Vince, the injector body works perfectly! no leaks!

Edit: what does it mean when it lurches and chugs forward at low rpm/low speed. It wasn't stalling but it chugged forward quite hard. It wouldnt drive slowly at a steady pace. And when i touched the pedal it took off....
Title: My much anticipated 1.6td/aaz head.
Post by: Rabbit TD on January 31, 2009, 12:34:32 am
Also congratulations from me too on your completion and it's outcome, I can't wait to feel the difference in my Rabbit when I put the new engine in, probably won't have the boost you have though. But I'm gonna keep reading and playing.  Good luck with it and I hope it stays together for a long time :D
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 31, 2009, 12:38:53 am
Thanks Rabbit TD  :D
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on January 31, 2009, 01:10:24 am
Quote from: "Smokey Eddy"
Edit: what does it mean when it lurches and chugs forward at low rpm/low speed. It wasn't stalling but it chugged forward quite hard. It wouldnt drive slowly at a steady pace. And when i touched the pedal it took off....


how much pedal are you giving it while its chugging/lurching??? you don't want to do too much of that (putting some good stress on the internals)... if it idles ok it should be fine.  if the low end torque wasn't there, i would suspect you need a bit more low end fueling, or adjustment of the governor.

the extra power that your experiencing is due in part to the 1.9 head flowing way better than the 1.6 head.   :wink: i'm real happy for you man!
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on January 31, 2009, 01:42:03 am
RIGHT ON ED!!!!
that's great news! glad you are boosting and having fun... :twisted:  8)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 31, 2009, 03:29:55 pm
Quote from: "jtanguay"
Quote from: "Smokey Eddy"
Edit: what does it mean when it lurches and chugs forward at low rpm/low speed. It wasn't stalling but it chugged forward quite hard. It wouldnt drive slowly at a steady pace. And when i touched the pedal it took off....


how much pedal are you giving it while its chugging/lurching??? you don't want to do too much of that (putting some good stress on the internals)... if it idles ok it should be fine.  if the low end torque wasn't there, i would suspect you need a bit more low end fueling, or adjustment of the governor.

the extra power that your experiencing is due in part to the 1.9 head flowing way better than the 1.6 head.   :wink: i'm real happy for you man!



I think the big difference is also the porting and polishing of the intake, head and exhaust mani.

when it does the lurching it's just rolling down a hill... and i'll be giving it like a very very minimal amount of diesel... very slight. no pedal = fine, lots of pedal = takes OFF, just enough to cruise above idle rpm on a downward sloe = lurch lurch lurch.

It still stalls without the cold start OUT unless it's completely up to temp.
it starts great though with the start out or in but without it out it will stall immediately after i stop cranking.  -  THAT makes me think it's a lack of fueling thing... OR could the pump be an entire tooth too retarded; because i pushed the pump as far as i could towards the head when i tried to fix the rough idle which you guys very accurately determined to be very retarded timing. I think i should try turning the fuel screw in just a smidge perhaps.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on January 31, 2009, 03:30:37 pm
I guess i can change my signature now  :D
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 01, 2009, 10:28:02 pm
Got the down pipe done this afternoon.
Yes, i wore slippers.
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX7833.jpg)
had to practice welding the cast. It was a fussy bastard!
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX7831.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX7829.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX7828.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/SSPX7834.jpg)

Now to sand blast, wire wheel, buff and paint it!
Wootsauce.
Title: My much anticipated 1.6td/aaz head.
Post by: gldgti on February 02, 2009, 02:30:04 am
Quote from: "Smokey Eddy"


It still stalls without the cold start OUT unless it's completely up to temp.
it starts great though with the start out or in but without it out it will stall immediately after i stop cranking.  


my buddies 1.6TD passat was doing this from too much advance - it was injecting and starting to fire so early that it would stall.... worked it out because if would work the the cold start IN.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 02, 2009, 03:29:18 am
but... it stalls immediately if i don't have the cold start out the moment i stop cranking...

meaning if i retard the timing back to normal by pushing the lever IN it will stutter and stall...
but it starts SO easily now... which makes me think its super advanced but then i think it's retarded because of the lever thing :evil:  augh!

maybe i just THINK it starts fast because the last time it was running it would take in excess of 15 seconds to start..?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 03, 2009, 03:48:36 pm
I can't wait to go get diesel at the gas station and not need to push start it when i want to leave!!!!!  :D  :D  :D  :D  :D  :D
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 03, 2009, 09:45:16 pm
Quote from: "Smokey Eddy"
I can't wait to go get diesel at the gas station and not need to push start it when i want to leave!!!!!  :D  :D  :D  :D  :D  :D


hmm... at that point i'd just leave the motor running while i refuel.  and maybe pimp smack anyone who tells me to shut it off  :wink:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 04, 2009, 01:36:30 am
I have a question about the cooling system.


 :(

I can hear my expansion tank hissing (ever so slightly). The rad is warm, the hoses are pressurized but have lots of air in them?
the exp. tank is between the marks.

im running straight water

the gauge in the dash doesn't register anything really... :S

the oil stays cool between 80-90 degrees C

Is the hissing because it is 100% water?

The tank and cap have less than 2,000 km on them.

I got so fed up trying to fix it that i bought a new head. ... didn't seem to do anything. I hope to GOD that the block isn't cracked... anyone have any ideas?

Do i need to run it for longer with the cap off? (i didn't run it for very long without the cap on, just long enough for (what i thought) for the t-stat to open.)

I'm also thinking the the T-stat could be malfunctioning at the same time because the hoses get hot seemingly too fast and the gauge never ever EVER reaches the middle.

My best guess is that because its 100% water it is boiling somewhere and expanding.
In comparison to how it's hissing now from when it was hissing with the old head i can only hear it . The old head would force water/coolant out of the exp. tank.


and im noticing the stuttering and lurching more now at lower rpm...  :(
Title: My much anticipated 1.6td/aaz head.
Post by: gldgti on February 04, 2009, 03:17:45 am
ok, cooling system -

when you fill it, you really need to take your time a bit and ensure that you're getting rid of air bubbles and stuff. park the car so that you give air bubbles the best possible chance to come to the top of the system and dont forget to open the heater tap. squease the top rad hose periodically and watch to see air bubbles coming out though the expansion tank. theres no harm in running the engine with the cap off the expansion tank for a long time to do this job properly.... it certianly shouldnt overheat! i had a small HG leak in my mk1 years ago that used to pressurise the system too much and blow hoses, so i just ran with the cap off - it was fine!

second - straight water will produce a bit more vapour when its warm than coolant will... so you will build vapour in the system earlier with straight water than you will with added coolant. any particular reason your're running without coolant?

finally, on your lurching thing - have you played with the governor? perhaps this is causing the unusual fuelling.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 04, 2009, 03:39:49 pm
i was using straight water because i was expecting to flush the system. I think i'll drain it and put 50/50 in it.


I played with the gov ages ago and drove it for a very long time without any issues....
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 04, 2009, 04:43:06 pm
100% water is pretty bad if temps go below 0 C.. could potentially crack the block even.
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on February 04, 2009, 05:24:20 pm
For what it's worth... here's Vince's magic incantation for filling MK2/3s that seems to result in very little turmoil over trapped air:
 
- disconnect the upper rad hose at the head and backfill the rad with a funnel in the upper rad hose.

This fills the rad up completely and without the closed t-stat trapping in bubbles.

- connect the upper rad hose back up to the head and finish filling via the coolant reservoir.  Fill to "min" at this point.

- leaving the cap off, start the engine and run it at a fast idle until you see steam rising from the coolant reservoir *and* the lower rad hose just becomes warm.  This signifies that the t-stat has finally opened.  You may need to add a bit of coolant to keep the level above the "Min" line... but don't overdo it and aim for the "Max" line.  If you go beyond "just warm" on the lower rad hose at this point the coolant may suddenly boil (since the system is not pressurized) and you'll have a geyser of hot coolant out the reservoir and all over your shiny new engine...BTDT.

- stop the engine and allow it to cool several hours... preferably overnight.  The cap is still off at this point... allowing any last bubbles a chance to vacate.

- with the engine cold, fill to the "Max" line, put the cap back on, and happy motoring !!!

I personally won't waste any more time troubleshooting until I had a proper antifreeze mix in the system... it will have significantly different boiling points etc and behave differently under pressure than pure water.  

My other thought is that I've seen many many many cracked coolant reservoirs... even brand new... and often the first clue is a faint hissing noise at standard operating pressure.  Soapy water will find those pesky cracks quickly, if they exist.  The lid can leak as well... went thru three once.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 04, 2009, 06:38:48 pm
Thanks Vince! I'll get that straight water outta there. It's probably had enough fun rusting away anyways by now.

The caps have a rubber ring in them that sometimes you just need to pull back to it's resting possition. It's how the cap releases excess pressure in over heat/pressurized coolant situations
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 05, 2009, 05:23:20 am
Just something to laugh at :P

You can all laugh at my stupidity here.

(http://i49.photobucket.com/albums/f279/edmcclung/DSC05065-1.jpg)
The blue indicates what kept blowing out at about 20psi. I fixed it with a barbed fitting that i threaded into the rubber hose.
SO then at 25psi the area indicated in RED split apart somehow? i guess i didn't clamp the two hoses together very well. I THINK i've fixed that... (im not doing anything fancy with it as it is temporary till i get around to doing intercooler/rad fans.)


and the yellow posses a question i have for you guys with that clear hose going to your boost gauge. How do you prevent this from melting? Is there some sort of sleeve you guys use or do you zap strap it somewhere?
as you can see i had mine taped for the time being.

Also, anyone reading this ever had issues with oil leaking from that oil line on the top of the turbo? in the red circle in my picture. I tightened it but it still leaked. Do I need to get it re-flared or something?
or do i need a new line :( .
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on February 05, 2009, 06:18:13 am
Take the copper washer out and heat it up with a torch till red hot then put it back and torque to spec.
Title: My much anticipated 1.6td/aaz head.
Post by: hamradio on February 05, 2009, 07:51:21 am
As for that hose, are you just using clear vinyl tubing?  If so, of course that is going to half melt at any sign on heat.  Vacuum line might be a better bet.
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on February 05, 2009, 10:08:23 am
come on ed....spend $10 and get a proper boost tubing kit...they can be had at just about any performance auto parts store...comes with the tubing, compression fittings and everything. 8)
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 05, 2009, 01:20:50 pm
i used the plastic hose for my turbo boost gauge, and after a year or so it hasn't melted.  it rubs against the valve cover too... it does have some discolouration where it contacts though... but other than that i wouldn't worry.
Title: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on February 05, 2009, 02:18:20 pm
Quote from: "53 willys"
come on ed....spend $10 and get a proper boost tubing kit...they can be had at just about any performance auto parts store...comes with the tubing, compression fittings and everything. 8)


^^^ x 2 ^^^
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on February 05, 2009, 02:36:59 pm
Or if you're anywhere near a NAPA their standard oil pressure gauge kit is about 6 bucks (Canadian!) and includes pretty good nylon tubing, compression fittings, etc.

In terms of routing... I make mine a bit longer than what you have and route along the small hose that goes to the coolant reservoir with a judicious number of zapstraps,  then thru the firewall.  This keeps it away from the back of the engine (and the heat that pours off the exhaust manifold) completely.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 05, 2009, 03:58:24 pm
Quote from: "zukgod1"
Quote from: "53 willys"
come on ed....spend $10 and get a proper boost tubing kit...they can be had at just about any performance auto parts store...comes with the tubing, compression fittings and everything. 8)


^^^ x 2 ^^^


I don't follow the point of spending ANY money on something that is so temporary? are you guys talking about my make shift 180 degree bend? or a sleeve for the line to the gauge?


Gee, that post sparked an enourmous amount of interest... I'm amazed!

I think i'll just zap strap it like vince suggested. I have some free line up in that box area where i have all the wires going behind the dash.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 06, 2009, 08:24:37 pm
Well i got an actual fitting and when it boosted hard it blew the fitting out, threads and all.


But my bigger worry is the enormous oil leak. It was leaking from the oil sender on the driver side of the head. I fixed that. ran up and down the street again and it's a constant drip from the back end. I checked the oil feed at the top of the turbo, it doesn't leak. I can't see oil anywhere on the turbo that i can see from my stand point with it in the car... Is there somewhere from underneath i should look for in specific? like where the cold side joins to the hot side?


There were 2 or 3 oil pan bolts i just couldn't get in because of how close the trans is to the oil pan (who's idea was that  :| ) Anyone have any ideas on how to get those in there? I tried a universal and it doesn't fit. A wrench - im not super human enough to turn at that angle.

anyone? :(

If it is leaking from the oil pan, do i have to drain the oil and take it all off again and clean off the gasket  :cry: and try again?  I'm really angry that VW designed it so that in order to take the pan off you need to take the trans off...

which leads me to think, "is it leaking between the trans and the block?"
to change that seal it's a massive job isn't it?

I put two of the bolts from the LDA that i replaced for actual bolts in the stead of the oil pan bolts and i got them in with a screw driver. BUT one of the holes was stripped :( so i guess i just gotta hard cheese it.
Title: My much anticipated 1.6td/aaz head.
Post by: truckinwagen on February 06, 2009, 10:55:30 pm
go to the fastener store and get some pan head phillips drive bolts the right size, then get a phillips driver for your ratchet, it will allow you to have the drive not lined up, but still drive the bolts in
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on February 06, 2009, 11:46:20 pm
Quote from: "Smokey Eddy"
I'm really angry that VW designed it so that in order to take the pan off you need to take the trans off...


Chill home boy... they didn't. :lol:  

1/4" universal and a 1/4" 10mm socket and bobs your uncle.  I've also done it with a straight 1/4" 10mm and a long, thin extension... but the universal joint makes it a bit easier.

In general, if it seems like something's impossible... it probably isn't... you just haven't figured it out yet.

Notable exceptions... yes, the power steering pump has to come off to change the t-stat, and yes the driveshaft has to come out to change the starter on an auto. :roll:

Anybody remember which car came with the Platinum plugs from the factory, because the engine actually had to be removed to change 'em ??!!  :shock:
Title: My much anticipated 1.6td/aaz head.
Post by: dubbinchris on February 07, 2009, 12:01:13 am
Quote from: "Vincent Waldon"


Anybody remember which car came with the Platinum plugs from the factory, because the engine actually had to be removed to change 'em ??!!  :shock:


Wasn't it the V6 Fiero?
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 07, 2009, 12:07:17 am
Quote from: "Vincent Waldon"


Chill home boy... they didn't. :lol:  

1/4" universal and a 1/4" 10mm socket and bobs your uncle.  I've also done it with a straight 1/4" 10mm and a long, thin extension... but the universal joint makes it a bit easier.



You must be a lot better at wrenching than me because i tried that and i couldn't get the socket on the bolt for the life of me.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 07, 2009, 12:07:51 am
Quote from: "truckinwagen"
go to the fastener store and get some pan head phillips drive bolts the right size, then get a phillips driver for your ratchet, it will allow you to have the drive not lined up, but still drive the bolts in



The LDA bolts bit perfectly and are slotted.
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on February 07, 2009, 12:20:58 am
Quote from: "dubbinchris"

Wasn't it the V6 Fiero?


That rings a bell... definitely a mid-engine as I recall.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 07, 2009, 12:22:15 am
vince is there any chance you could email me a higher res. picture of your avatar?
Title: My much anticipated 1.6td/aaz head.
Post by: Vincent Waldon on February 07, 2009, 12:30:02 am
Quote from: "Smokey Eddy"
vince is there any chance you could email me a higher res. picture of your avatar?


It's the brilliant work of Peter Aschwanden (http://www.peteraschwanden.com/) from the "Keep Your Rabbit Alive" book.

The funny thing is, when I first started driving diesel bunnys (in my case, a Rabbit pickup)... that's exactly what it was like.  Diesel was only available at truck stops, and I always sandwiched between an audience of truckers, one of whom might come over to warn me that I was filling with diesel... until they saw the DIESEL badge on the tailgate.  Then at least half the time they'd pull out their wallet and offer me cash on the spot for my tiny truck.

Ah..... memories :wink:
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 07, 2009, 05:41:16 am
that's a cool story  :P

I'm still surprised how many people don't realize that like ~40% of the newer jettas and golfs out there right now (at least where i live) are all TDI and they run on DIESEL.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 11, 2009, 05:12:06 am
:D

got day insurance for the 11th. It's now 2am and i've put about 80km on it! ha!

I fixed the lurching by turning the fuel screw out 180 degrees. It sounds more like a throaty diesel now and idles at (mine and my dad's guess) 900rpm.

Still accelerates great. The polished/ported aaz head and 2.5" downpipe make the T3 seem not so big until you look at the boost gauge or stick your head out the window and hear the GLORIOUS whistling of the turbine.

I saw 700F on the EGT at 120km/hr on the highway. WOT it never got above 800F for holding WOT until the boost went over 10psi. I can't get the fitting to stay in the hose to the intake manifold. (fixing that tomorrow before air care)

The oil temp stays extremely static. It never seems to waver even with erratic driving.

The lag with my set up from a stand still once i let the clutch all the way out is about ...2 seconds to see 10 psi and then another 2 or LESS to see 20 and then im usually in 2nd by then and i don't want the boost to go up anymore because it keeps firing that fitting out.

a smoothed out intake, exhaust and AAZ head with a big down pipe on a 1.6 make for very very very little turbo lag. when it revs up it's just totally different than it was before. I can't believe how much has changed with this new head.


The only issue im having is a pretty harsh oil leak which i can't see at all where it's coming from. the drip pattern seems to be all over the back of the oil pan and the belt side. I'm going to run it with the cover off to see if the cam leaks or intermediate shaft leaks etc. I'm pretty sure it's coming from the back of the cam cover like Vince has mentioned before and i will be putting carriage bolts through it all in the near future. I'll do a DIY on it too i think just for fun and it's so simple.

Another problem is the coolant/temp light is still ALWAYS flashing and my alt. light flickers very dimly. any suggestions? I don't know what the dim flickering batt light means and I'm totally lost with the temp light. I've given up with it. I think something is just broken causing it to forever blink. The temp stayed wonderful - like i said the oil never got hot but i did notice the hoses never got hard and (YAY!) the expansion tank didn't hiss at all.
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on February 11, 2009, 06:17:29 am
800 degrees doesnt seem right.If your fuel is turned uo then you should see at least 1100 degrees on a pull if not 1300.
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 11, 2009, 12:10:24 pm
Quote from: "dillenger1"
800 degrees doesnt seem right.If your fuel is turned uo then you should see at least 1100 degrees on a pull if not 1300.


because of all the porting, and extra airflow, it might just be running more efficient... especially with that larger downpipe he has installed.  

is there any black smoke when you drive, Ed?
Title: My much anticipated 1.6td/aaz head.
Post by: 53 willys on February 11, 2009, 01:06:50 pm
me and eds set-up is not the same so take this for what is worth..
but I cruise at 75mph and my EGT's are 600*-800*...but if I get on it hard for a big WOT run my EGT's will hit 1200* if I'm not careful..my head in PNPed and I have a FULL 3" exhaust.
But I also have a Bigger laggyer turbos...sooo...
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 11, 2009, 04:02:30 pm
Quote from: "dillenger1"
800 degrees doesnt seem right.If your fuel is turned uo then you should see at least 1100 degrees on a pull if not 1300.


it's just a downpipe and nothing else. the exhaust ends before the front doors start pretty much :P
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 11, 2009, 11:10:31 pm
oh man exhaust systems suck so much!

i turned the fueling down for air care + added the exhaust system and it wont make more than 10PSI of boost now and very slowly... no more boost at highway speeds. The coolant light stopped flashing after 130kms. The batt light still flickers though, i gotta search up on that.

and i wrecked the CV's already. terrible vibrating noise on take offs. (when there is the most torque im assuming?)

It runs very nicely now. Starts FIRST crank which still scares the crap out of me... don't need the timing advance out anymore to idle. doesn't smoke on idle anymore.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 12, 2009, 04:05:58 pm
Quote from: "jtanguay"
Quote from: "dillenger1"
800 degrees doesnt seem right.If your fuel is turned uo then you should see at least 1100 degrees on a pull if not 1300.


because of all the porting, and extra airflow, it might just be running more efficient... especially with that larger downpipe he has installed.  

is there any black smoke when you drive, Ed?



Sorry i didn't see this till now.

NO! Unbelievably there is not at all (that i can see?). It smoked about as much as my parents 2000 ALH TDI under WOT but once it got the boost there it was perfectly clean. The only time it smoked is on cold start ups it will burn white and stingy to the eyes. And i'm putting the cause for that very confidnently on the new rings and compression difference. I still can't get over the start up on FIRST compression stroke. When it's hot it literally starts on what must be the first compression stroke. My friend who's been helping me from the begining almost shat himself when i started it up again at his place when i picked him up for a spin while i still had day plates. It actually smokes significantly more with the exhaust rammed onto the end of my DP because it can't make the boost as easy.

I hope that is inspiration to port/polish your head + manifolds next time you get the chance :P
Title: My much anticipated 1.6td/aaz head.
Post by: ObscuredByClouds on February 12, 2009, 09:16:20 pm
man.. I don't like to see this happening
Title: eddy?
Post by: vixentd on February 12, 2009, 09:19:42 pm
Where are you located in Abby?  I am in abby also.  .
Wouldnt mind seeing your motor.

One of my rides even comes with the kitchen sink!!! 2.4 diesel  bmw turbo

www.vixenrv.org
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 12, 2009, 09:29:27 pm
Quote from: "Smokey Eddy"
Quote from: "jtanguay"
Quote from: "dillenger1"
800 degrees doesnt seem right.If your fuel is turned uo then you should see at least 1100 degrees on a pull if not 1300.


because of all the porting, and extra airflow, it might just be running more efficient... especially with that larger downpipe he has installed.  

is there any black smoke when you drive, Ed?



Sorry i didn't see this till now.

NO! Unbelievably there is not at all (that i can see?). It smoked about as much as my parents 2000 ALH TDI under WOT but once it got the boost there it was perfectly clean. The only time it smoked is on cold start ups it will burn white and stingy to the eyes. And i'm putting the cause for that very confidnently on the new rings and compression difference. I still can't get over the start up on FIRST compression stroke. When it's hot it literally starts on what must be the first compression stroke. My friend who's been helping me from the begining almost shat himself when i started it up again at his place when i picked him up for a spin while i still had day plates. It actually smokes significantly more with the exhaust rammed onto the end of my DP because it can't make the boost as easy.

I hope that is inspiration to port/polish your head + manifolds next time you get the chance :P


also sounds like the rings seated very well.  you did hone the bores right?  did you lube the bores, or install dry?  just curious.

yea my mTDI burns a bit white and eye stingyness as well.  could be due to my chinese nozzles though  :cry:

most people think eye stinging is bad from exhaust, but not all the time.  the pH in your eyes is not pH of 7, which is neutral.  the exhaust from the car should be neutral, unless you're running a different kind of fuel  :lol:
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 12, 2009, 11:10:40 pm
Quote from: "Smoky Eddy"
It actually smokes significantly more with the exhaust rammed onto the end of my DP because it can't make the boost as easy.



Well when you get her passed the AIR CARE B.S, rip that stuff off and throw it in your trunk incase you get pulled over :) then you can tell the cops "yeah it JUST fell off" lol Did you get it passed Air Care yet?

Jeremy
Title: My much anticipated 1.6td/aaz head.
Post by: arb on February 13, 2009, 08:13:02 am
I'm sure glad we don't have emission testing in SE Michigan anymore... it was just a money waster - any car that didn't pass would be OLD, and if its an old car, the mechanic could sign off saying it was too expensive to fix and you'd keep on driving. The rest of our state never had inspections.

I'm not sure how they used to handle inspections on "assembled vehicles" - which is how I'll need to re-title my Caravan with the IDI diesel to be EPA legal, even here.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 13, 2009, 04:30:07 pm
Quote from: "NoSurrenderAG"
man.. I don't like to see this happening



 :(  Seeing what happening?
I'm quite pleased.... do explain...


Air care is an embarassing story... My old highschool shop teacher was kind enough to let me use the lift at the school and the really nice MIG they have (oh god i love that welder...). it took until 4:30 to get it all together starting at close to 3 (I couldn't do it while he had classes right). Flew down there and i was 5 minutes late  :cry: they had closed the doors...

oh well. Another 26$ I guess :roll: .

vixentd! Heehee kitchen sink?! I'm up the hill from Robert  Bateman Secondary. When you go up Sandy Hill Rd. and look up, that row of houses that looks directly down onto Sandy Hill Rd. is where i live. Gimme a PM and we should meet up and you can see my sad excuse of a VW.

Jer, I don't think the cops really do too much because diesels are just expected to smoke. Zukgod1 has a hilarious story of being pulled over with his KIDS because he was "smoking too much". I think he had to go to court over it!!! Poor Fella... And it's not even like his is a rust bucket in need of a VI, his is one of the cleanest mk2s i've ever seen.

Here is my exhaust idea!!

2.5" downpipe goes to a 3 inch Y which splits into two 3 inch sections that go on as shallow of an angle as possible out to the back tires and then 45 degrees outward right at the edge! and cut the pipe flush to the body lines like blkboostedtruck has his. Except mine would be on both sides.

THAT way, when i turn the fueling as HUGE as it will go! It will look like im doing a burn out all they way up to like 120km/hr. 5th gear burn out, now THATS impressive! :wink:
Title: My much anticipated 1.6td/aaz head.
Post by: vanbcguy on February 15, 2009, 03:54:34 pm
Just for the record, Burnaby RCMP pulled me over for too much smoke.  It was less than a day after I'd gotten the car and it really wasn't tuned well so yeah, there was a fair amount of smoke, and I'd just floored it off a light on Willingdon.  The officer that pulled me over was a commercial vehicle inspector so she was VERY familiar with diesels.

I didn't get a pollution ticket, but I DID get a mandatory vehicle inspection ticket.  The inspection ticket doesn't have any fee associated with it, but the inspection itself is about $100.  Ended up needing 2 new tie rods and my backup light switch replaced to pass, total cost about $500 including the inspection fees.

My car doesn't look particularly dodgy or anything, she just wanted to get me with SOMETHING for the smoke. YMMV...
Title: My much anticipated 1.6td/aaz head.
Post by: dillenger1 on February 15, 2009, 04:21:16 pm
Do you guys have an opacity test for "air care"?We have e-check in the states.They rate you on a 20%opacity limit,my truck was 3.4%.
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 15, 2009, 04:36:21 pm
Quote from: "dillenger1"
Do you guys have an opacity test for "air care"?We have e-check in the states.They rate you on a 20%opacity limit,my truck was 3.4%.


is that 20% at idle? or do they actually put it on a dyno?
Title: My much anticipated 1.6td/aaz head.
Post by: vanbcguy on February 15, 2009, 05:34:33 pm
We have an opacity test and a "visual" test.  The "visual" test just makes sure your car has a cat if it came with one (all the AAZ's had cats) - automatic fail if it's missing.  Opacity test is 30% on a dyno.  Not sure if it's "average 30%" or "peak 30%"
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 15, 2009, 08:32:21 pm
Probably peak? who knows.


$500 jesus ... what a load.

i need a new reverse switch but i don't care enough to get one. I'm a fan of VI's because i dont want to drive on the same road as someone with a car that doesn't have brakes but if i got one the repair cost would be unimaginable... I need all sorts of suspension/steering work. It drives just fine but i probably need wheel bearings, a CV joint, and strut bearings (those rubber things ontop of the strut). When i turn too far right or left i hear a big CLUNGGGGGGG and the steering wheel will pull right or left a little bit. I've been told that that is a strut bearing problem. I would get a new one but i dont know where to get one for less than like $1,000. Anything at the VW shop in abbotsford is about 300% mark up from what you guys quote. I would use http://www.importcarpartscanada.ca but i don't need enough items to make the shipping worth while... or the money to buy it  :roll:
If I got a VI I would be totally screwed. No more car. And my windshield is cracked.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 15, 2009, 09:04:01 pm
a cv joint is 80$ plus :(

can anyone tell me which part no. on www.importcarpartscanada.ca i want for my car for a wheel bearing? I want to do both front ones while im at it.

There are like ... so many different ones...


here which ones to i want? I dont have an auto trans.
(http://i49.photobucket.com/albums/f279/edmcclung/wheelbearings.jpg)
Or, do i want a kit?
(http://i49.photobucket.com/albums/f279/edmcclung/wheelbearingkit-1.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 15, 2009, 09:35:50 pm
yo, Ed-man.

I think it would be wise to get a kit if it offers every thing you need for bearing, and axle replacement.. i've heard you should never use all that stuff again.. but i have used them atleast 3-4 times for various reasons to remove axles.. depends on your budget i guess bud.

If you look at the KIT pieces it says for the front you need the 72mm dia. bearing for the front.. so if you want to do it alone then you need the one bearing from your list that is 72mm :P

When i got my bearings done i supplied the two bearings to the shop i had do them and he did the work with no parts cost, and i got him to do the alignment as well.. altogether was like 125 dollars.. 50 for alignment, and 75 or so for his labour. no parts charge.. turns out the bearings he was gonna get were like 20 dollars more too.. pheww :P

Goodluck, do you need some help? I could get on a plane tonight and see you in a few hours? :lol: I could hold something while you weld it eh? :p

Jeremy

LMAO

EDIT! wait a second here Ed.. how can cv joints be $80 when the whole damn axle is like $95? ED! You never make sense!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 15, 2009, 09:38:19 pm
HAhahahaha Do it man. We could both do work for people on their VW's! That would solve our unemployment! although it would take a long while for you to just pay off the ticket cost ...  :roll:

Thanks for the input. So if i wanted to change the two front bearings i would order two of the 72mm bearings?

Don't they need to be pressed on?
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 15, 2009, 09:40:43 pm
Quote from: "Smokey Eddy"
HAhahahaha Do it man. We could both do work for people on their VW's! That would solve our unemployment! although it would take a long while for you to just pay off the ticket cost ...  :roll:

Thanks for the input. So if i wanted to change the two front bearings i would order two of the 72mm bearings?

Don't they need to be pressed on?


Ohhh unemployment :(

Yeah pressed in by a shop.. sadly not ALL the work on these cars can be done at home..
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 15, 2009, 09:43:39 pm
dang it. I have acess to a 3 ton press at my old highschool... can i just take the parts to my school and press them my self? or do they get pressed with all the stuff still on the car? I've never seen that part of the car apart before so i dunno what it looks like,.
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 15, 2009, 09:54:39 pm
it has to come off the car.. and you have access to a press! woohoo, easy peasy.

Take the tire off, take the caliper off, unbolt the two bolts holding the bottom of the spring assembly in, pop the ball joint, and then the tie rod. i think thats all that holds that steering "knuckle" in there really.. once you start tearing in to it, it should come apart like cheese. I mean you did a head swap, and i could do what i am describing, i wouldnt try a head swap.. you should be be good :P

cough* get some beer for the job *cough
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 16, 2009, 12:28:12 am
i havent a clue what my avatar is man :( nobody knos :lol:

its weird i found him over on the vortex, art and design forum. lol
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on February 16, 2009, 01:02:54 am
Quote from: "Smokey Eddy"
dang it. I have acess to a 3 ton press at my old highschool... can i just take the parts to my school and press them my self? or do they get pressed with all the stuff still on the car? I've never seen that part of the car apart before so i dunno what it looks like,.


you need to remove the spindle assembly to press the new bearing if you intend on using a shop press... but it is not simply the pressure that you need.. you need a piece that is a perfect fit to press out the bearing.  someone with machinist skills could probably make a tool though...

but there is a good writeup here on vortex (http://forums.vwvortex.com/zerothread?id=1722551). maybe the only thing i would try and avoid, is having to take off the ball joint... especially on an old beast.  you'd need to take a wire brush to clean off the rust just so you could make the scribe marks, or just paint it.  that guy makes it look too easy.. theres not enough rust on that car!!!  :lol:

i bet you could probably rent the bearing puller from c-tire if you buy the part from them.  probably dirt cheap rental too, if they're not jackasses.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 16, 2009, 06:26:07 am
Holy crap thats a way bigger job than i thought.

I really appreciate you finding that thread for me. It's convinced me to NOT do that my self ... I dont have a 30mm socket or that puller contraption. I think i'll just get the two bearings and get a shop to do it. If Jeremy got it done for 75$ + 50$ for an alignment i guess add 75$ for doing it twice and that's $200. for two wheel bearings. and that's just a guess!!! :P I think i'll wait until it's a real issue. I should figure out the steering thing first i think.

Thank you all very much for the input and that thread jtanguay. Bookmarked.

I'll see if my old shop teacher has the 30mm socket :P and possibly the bearing pulling stuff! We'll have to see.
Title: My much anticipated 1.6td/aaz head.
Post by: theman53 on February 16, 2009, 08:09:10 am
If you have the socket, welder, air chisel, press and 2 people you can do it with the knuckle on the strut. I did it 3 times now. I am too cheap to want to get it aligned if you take the knuckle off you almost have to get it done.
If you knock out the center of the bearing with air chisel or press and then all that is left is the outer race. Take you mig and lay a nice heavy bead around the entire inside of the race that is left in the knuckle. Then before it cools take your air chisel and hammer out the race *make sure to take the snap rings out first* and be careful not to hold onto it when it falls as it should be hot. Clean up the inside of the knuckle. Head over to the press and take you old race if you have to use it to press. Have one guy hold onto the strut while the other runs the press. Monkey around and you should be able to get it in there straight with no problems.
Remember to get the axle nut on there good. I always use a threadlocker. Let me know if you have any questions. LOL
Title: My much anticipated 1.6td/aaz head.
Post by: foxracer1 on February 16, 2009, 08:36:30 am
Quote from: "Smokey Eddy"


can anyone tell me which part no. on www.importcarpartscanada.ca i want for my car for a wheel bearing? I want to do both front ones while im at it.

There are like ... so many different ones...


What year is your car?  MkI cars get a smaller bearing eaarly
MkII(85-85) get a medium bearing
late MKII(88-up) and MKII(not sure about vr6) get a larger one
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on February 16, 2009, 01:53:28 pm
'90 so the 72mm one?

i had to enter my year & model and stuff into the site for it to give me a parts list.
Title: My much anticipated 1.6td/aaz head.
Post by: doc.gneoson on February 22, 2009, 01:06:55 am
hey ed,awsome thread!,  you replied to someone saying something along the lines of "don't worry the block is soft and drilling though it is easy", i can't find it again to actually quote it(sorry lol), what did you have to drill and for what, or do i got it totally wrong, if you have no idea what i'm talking about don't worry about it i was prob a few months ago lol
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on February 22, 2009, 09:47:11 am
i beleive sir ED-mon had to drill for steam passages.. if i am not mistaken :)

Welcome to the Forum Doc.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on March 12, 2009, 05:03:35 pm
I didn't have to. I chose to because the AAZ head has em.

I found out why my gauge said i have an oil temp of 210F... the wires were just EVER so slightly crossing for the power to the lights and the feed line. When i turn the dimmer down on the gauges the needle goes down! Hahahaha

yeaahhhh....

So i finally got the line to the IP to stop coming out of the intake hose. JB weld to the rescue. Unfortunately at 25+ psi two hoses i have clamped together keep coming apart. I also just finished changing my dash lights to red LEDs. I'll take pics tonight in the dark and post a thread about it!

The job was a complete success despite taking like 5 months.
Title: My much anticipated 1.6td/aaz head.
Post by: subsonic on March 12, 2009, 05:45:57 pm
I drilled my 1.6mf block for them as well.  Lay the aaz gasket on top, mark them, drill them.  They line right up with the holes on the aaz head.  Cant hurt.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on March 12, 2009, 05:48:19 pm
The iron is extremely soft as well. You could use wood bits.
I drilled mine a little large than i was totally comfortable with. I'd go slightly smaller diam than the holes in the HG.
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on March 17, 2009, 11:47:41 pm
Yay!

(http://i49.photobucket.com/albums/f279/edmcclung/LED%20Dash%20Lights/DSC05129.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/LED%20Dash%20Lights/DSC05125.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/LED%20Dash%20Lights/DSC05127.jpg)

JB weld to the rescue.
(http://i49.photobucket.com/albums/f279/edmcclung/LED%20Dash%20Lights/DSC05128.jpg)
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on April 26, 2009, 07:40:42 pm
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7933.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7933.jpg)
Thanks Theman53, you're the man :D
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7932.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7932.jpg)

See, my car actually works :P
Title: My much anticipated 1.6td/aaz head.
Post by: lord_verminaard on April 27, 2009, 09:46:30 am
Wire nuts in the engine bay make me cry a little.....


Brendan
Title: My much anticipated 1.6td/aaz head.
Post by: jtanguay on April 27, 2009, 10:45:39 am
Quote from: "lord_verminaard"
Wire nuts in the engine bay make me cry a little.....


Brendan


yea it should be done with a nut & bolt with crimped/soldered end pieces and shrink wraped if possible, but it looks alright.  it fits right in with the budget build  :) but not ghetto  :lol:
Title: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on April 27, 2009, 11:14:29 am
Ghetto is the way to be  :lol:

Ed, your cars to clean, splash some oil on the head will ya? lol
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on April 27, 2009, 01:40:26 pm
Quote from: "jtanguay"
Quote from: "lord_verminaard"
Wire nuts in the engine bay make me cry a little.....


Brendan


yea it should be done with a nut & bolt with crimped/soldered end pieces and shrink wraped if possible, but it looks alright.  it fits right in with the budget build  :) but not ghetto  :lol:


I don't have a lot of money ok! :P
I found those in a bucket in the basement.
That's also solid house hold wiring  :D
(but its gone now)
Title: My much anticipated 1.6td/aaz head.
Post by: TurboJ on April 27, 2009, 06:41:50 pm
Nice!
So how does it run now?
*Videos please* !!
Title: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on April 27, 2009, 08:10:38 pm
siigghhh ok...
i weld the exhaust on friday though!

Edit: Welding got postponed :( next week...
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on May 22, 2009, 01:56:44 am
Yeeeeuuughhhh the welding keeps getting pushed back and back i dont think i'll ever get it done...

I just calculated my mileage and its about 45mpg (+/- 5).
It has over 4,000 kms on the build so far. I'm about to roll over to 400,000!!! I'll try and get a video of that :P

I just changed the crank pulley while the forum was down. This is what the old one looks like :P note the sheared off bolt from a PO and the cracking. The crack went all the way down. I broke two sockets getting the bolt off and lifted the car off of the jack stand it was on  (thankfully back down ONTO the jack stand...) with the help of my friend just GIVIN ER on the cheater bar to undo that bolt. An impact gun didnt do it either. but we used the impact socket since it would be of higher grade than my cheapo sockets and it worked like a charm  ;)!!!!
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7945.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7945.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7944.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7944.jpg)
The tool of course. Anyone can have this now that im done with it. Cost of shipping and the flat bar please! I'm a poor student! Just look at my car :P
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7948.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7948.jpg)

And my exhaust that i can't weld....  :'(
I paid 76$ CAD for all this pipe. It's 2.5 inch and that's a 10 foot length. Don't ask me how ;) i just owe my friend a huge favor come time to rebuild his 5.0L jeep's tranny.
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7947.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7947.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7949.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7949.jpg)

And my long awaited project, the BIG flat fans! Here is the lay out of the bracket that should match up on the Radiator. I just need to drill the bolt holes and weld it.
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7950.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7950.jpg)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 20, 2009, 12:12:44 am
Woo hoo!
some interesting pictures.


dual side exit!
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7972.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7972.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7973.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7973.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7967.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7967.jpg)
Don't laugh at the welds! It's not what i do for a living okay? :P
ps those are not the final welds. I did a full pass around and then ground the welds and then did a 2nd pass. No leaks! :P :D

Fixed my bursting hoses for much much bigger ID pipe. Yes its ABS plumbing pipe.
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7960.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7960.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7959.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7959.jpg)
and i drilled and tapped my intake for the LDA.

Just need a video of a wicked burn out with the exhaust just PUMPING out the sides :P

my next project! Bolt on flood lights!
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7975.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7975.jpg)
 ;) Yes Vince, they are princess Auto! $40 for the two!
Title: Re: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on June 20, 2009, 12:17:36 am
YESSSSSSSS EDNAAA

I was thinking of doing the same to get a dual pipe... ACTUALLY!

How did it work out in the end? how do you have it secured to the car? Bolted through the floor or what? Sheet metal screws? lol Give me your secrets!!!  :P Hey.. if the weld holds.. its a good weld :)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 20, 2009, 12:19:58 am
i used steel All-Round on the cross member at the back and the stock hanger location that is just past the cross member at the back. It rumbles against the cross member on idle which i need to fix (just tighten the all round with the help of a friend, you should come over.) but other than that it's great. It can blow 1m wide balls of soot probably 10-14 feet out the sides when it's just sitting still with a quick foot to the floor in neutral :P i really need a video but it rained today and is pretty dark now.

i cut my down pipe down because it was too heavy and put the flex on the DP then i butt welded a coupling to the flex and the main piece (the 10 foot cut down with the Y and sides) slides into the coupling and then i keep it in place with just those two hangers. Surprisingly i haven't needed to keep it from spining in the coupling but im sure i will need to do that. But it's drivable now! and no diesel stink! uhh i mean... i unfortunately dont get to breath diesel exhaust through the vents anymore in my 2.5 hours a day of commuting... ::)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on June 20, 2009, 02:43:16 am
Floodlights where the roof rack used to be sounds good BTW!

When you coming down Ed? gotta make me an exhaust.. and do some work on a Muscle Car :P Manual Drums on all four corners :)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 20, 2009, 03:39:03 am
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7977.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7977.jpg)
not replacing the roof rack ...
i just blinded my self testing them out side.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: theman53 on June 20, 2009, 10:52:54 am
Crawl under that thing and get me a picture of what it looks like under that car already  ;D . I was thinking about this but I wanted to try a 45 instead of a 90 and then at the exit cut the pipe at a 45. Oh and I am going 3" but I would probably reduce it to 2" at the split. Looks good
Title: Re: My much anticipated 1.6td/aaz head.
Post by: 8v-of-fury on June 20, 2009, 11:47:54 am
Your car will look like A BOSSSSSS!  :-* lol
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 20, 2009, 03:01:02 pm
Crawl under that thing and get me a picture of what it looks like under that car already  ;D . I was thinking about this but I wanted to try a 45 instead of a 90 and then at the exit cut the pipe at a 45. Oh and I am going 3" but I would probably reduce it to 2" at the split. Looks good

you gotta really make sure the DP comes out dead straight and dead in the middle or else you run into problems like im having with the cross member at the back. the pipe wants to sit lower down because of the bump in the heat shield for the shift linkage. but my DP isn't low enough to it rubs against the cross member on idle.

pretty sure my parents took the camera to england with them so all i have is my crap cell phone.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: docadillac on June 23, 2009, 12:40:13 pm
This is a great thread Eddy! I love the fact that you were able to do the work yourself. I have a couple of Q's on your 1.9 head. Is it hydraulic or mechanical and were the guides already in? Oh yeah before I forget, I saw that you had an intercooler in your earlier posts. Did you attach it to the turbo system or are you running the turbo without it? Sorry if these are stupid Q's But I'm trying to get as much info as I can, thanks.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 02:09:20 pm
This is a great thread Eddy! I love the fact that you were able to do the work yourself. I have a couple of Q's on your 1.9 head. Is it hydraulic or mechanical and were the guides already in? Oh yeah before I forget, I saw that you had an intercooler in your earlier posts. Did you attach it to the turbo system or are you running the turbo without it? Sorry if these are stupid Q's But I'm trying to get as much info as I can, thanks.

The head did come with the guides already pressed in. And it is hydraulic. I made sure of that because i didn't want to somehow block off that second oil hole on my hydro block :P

The intercooler is off a volvo and it's really big. I'm having a hard time finding somewhere it will fit. I've picked up two thinner fans that i need to make a bracket for (im in the midst of making the bracket)
but a top mounted IC off a talon or DSM would be much easier. Just need to cut a square in the hood and find a scoop ^.^

ps. I've been having lots of fun with other things lately though such as ... i wired a power inverter into the dash. and i added a second battery (i just need to find [or make] a hole through the fire wall) and i added two huge flood lights that have the wiring hidden in the weather stripping and can be easily unplugged to remove the lights from my roof rack. I fitted them so my doors still open but the canoe will still fit on the rack! It's pure genius! and looks hilarious (big 6 inch round flood lights on a flat black lowered jette? come on ...)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: docadillac on June 23, 2009, 02:15:41 pm
Thank you Eddy. I would guess mounting that intercooler would be space consuming so where could it go?? Do you think in front of the radiator would be a good place or would it not fit because of the radiator support size as in too thin?
Title: Re: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on June 23, 2009, 02:16:02 pm
but a top mounted IC off a talon or DSM would be much easier. Just need to cut a square in the hood and find a scoop ^.^


Oh PLEASE dont do that Ed... Please.....
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 02:17:29 pm
Thank you Eddy. I would guess mounting that intercooler would be space consuming so where could it go?? Do you think in front of the radiator would be a good place or would it not fit because of the radiator support size as in too thin?

Yes, the point of the thinner fans is to be able to move the rad backwards towards the oil filter and then cut as little as possible out of the grill support to fit the IC.

Haha ok dan, i wont. A big silver tooth through my euro bumper would look good no? (but them's mighty expensive)
Title: Re: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on June 23, 2009, 02:22:43 pm
I bought both mine off E Bay and I dont think I paid more than $75. for either.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: docadillac on June 23, 2009, 02:30:09 pm
Thanks Eddy. There is a twin fan set-up from a different vw on my buddy's ride. It's an 86 Jetta gasser. He's got a 1.6 turbo diesel sitting in a car that took a side hit. The body on the 86 is in pretty good shape except for some rot on the A pillars. The plan is to transplant the turbo engine and 5 speed manual tranny after the engine is rebuilt. I like what you did with the ALH intake manifold it looks like a really good fit.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 02:34:37 pm
I bought both mine off E Bay and I dont think I paid more than $75. for either.

Teach me your wisdom! :O perhaps i should make an account...
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 02:57:18 pm
For what it's worth;
with that much extension of my exhaust  from the down pipe i've noticed EGT's to be about 200 degrees hotter on average. 120km/hr in 5th is at about 750F. My hill climb course (The Highlands from the bottom of McKee for those Abbotsford guys on here!) it will climb to 1,200F and just sort of sit... never gone higher than 1,250F

Just some insentive to have dual 2.5 inch ahahhaha i have 2.5 inch exhaust to the cross member then from there it is two 2.5 pipes. I dont feel like doing the math but it's pretty free flowing. On start up the only issue is that its TOO free flowing and it's rather loud (popping sounds as air pockets get stuck) but once it idles for about 20 seconds or i start driving it goes away. It can really make driving feel weird :P
Title: Re: My much anticipated 1.6td/aaz head.
Post by: zukgod1 on June 23, 2009, 03:29:14 pm
http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-Front-Mount-S13-S14-S15-SILVIA-EVO_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a1Q7c293Q3a1Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fb7c137QQitemZ250445545783QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-27x6x2-5-BMW-E30-E36-Audi-A4-A6_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a0Q7c293Q3a2Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fc12015QQitemZ250446159893QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-25x12x3-Civic-Supra-S13-Mustang_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a0Q7c293Q3a2Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fc11a3aQQitemZ250446158394QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 03:45:47 pm
Thanks Dan!
With shipping those would all be well over $100 US especially to me in Canada. I could get a DSM intercooler for very very cheap.
But i like those ones. Which would you think would be best? the third one i dont think would fit... The second one looks alright but it's quite small. The first one? :D
Title: Re: My much anticipated 1.6td/aaz head.
Post by: rallydiesel on June 23, 2009, 03:53:19 pm
Got my AAZ head so there will be another frankenmotor on the road! Just tearing it down and I will start porting the exhaust.  ;D
Title: Re: My much anticipated 1.6td/aaz head.
Post by: 53 willys on June 23, 2009, 04:14:43 pm
I used a 28x7x2.5 inch Intercooler  from CXracing.......dont get to big of a IC...it will just make for more lag...
Title: Re: My much anticipated 1.6td/aaz head.
Post by: Smokey Eddy on June 23, 2009, 04:59:43 pm
Got my AAZ head so there will be another frankenmotor on the road! Just tearing it down and I will start porting the exhaust.  ;D

;D
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: zukgod1 on June 23, 2009, 06:13:35 pm
I'll second what Mark said.

The small one would be fine Ed..
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on June 23, 2009, 09:08:38 pm
I'll second what Mark said.

The small one would be fine Ed..


I hear you Bravo Leader!
That's still some decent coin for me though. Considering i would need piping too. Or, i could just use more ABS right? with the rubber couplings?

I live really close to the border so i could get it shipped to this place called "ship happens" to save on shipping/duty and what not.
it would be $100 cad with the x-change rate right now. That's not bad at all. I thought my dollar was a lot less then your dollar :P
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: jtanguay on June 23, 2009, 09:22:32 pm
I'll second what Mark said.

The small one would be fine Ed..


I hear you Bravo Leader!
That's still some decent coin for me though. Considering i would need piping too. Or, i could just use more ABS right? with the rubber couplings?

I live really close to the border so i could get it shipped to this place called "ship happens" to save on shipping/duty and what not.
it would be $100 cad with the x-change rate right now. That's not bad at all. I thought my dollar was a lot less then your dollar :P

go to cdn tire and buy the exhaust piping for the turbo to intercooler.  you can use abs from intercooler to intake, as it won't be as hot, but it could still melt and burst. the 2.5" exhaust piping should be perfect, and you can crimp the ends for a good seal :)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: theman53 on June 23, 2009, 10:12:09 pm
My hillbilly ways of thinking are leaning me to the exhaust pipe and radiator hose. I know the exhaust can handle temps and the radiator hose handles coolant at least 200 degrees F day in and day out. Plus I can find radiator hose just about anywhere and I know it doesn't get torn up too easily...the only thing I have yet to find out is how much stretch??? If the radiator caps have a 13-16psi rating then the hose should handle more than that, I hope.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on June 23, 2009, 10:41:01 pm
Well i already have ABS pipe and rubber couplings going from the turbo to the intake the way it is right now and they haven't melted. They just get formed to that shape.
ie. when you take them off they are fitted to that shape permanently.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: docadillac on June 26, 2009, 04:53:53 pm
Eddy I had read that you got a new camshaft as well as the head. Was it the 1.9 cam or another 1.6. If it was the 1.9 does the profile of the cam remain the same as the original 1.6 as in the timing of the valves opening and closing?
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on June 29, 2009, 03:19:34 am
I did not get a new cam as my 1.6 cam fits just fine and was not worn at all.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on July 05, 2009, 06:54:43 pm
http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-Front-Mount-S13-S14-S15-SILVIA-EVO_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a1Q7c293Q3a1Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fb7c137QQitemZ250445545783QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-27x6x2-5-BMW-E30-E36-Audi-A4-A6_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a0Q7c293Q3a2Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fc12015QQitemZ250446159893QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

http://cgi.ebay.com/ebaymotors/CXRacing-Intercooler-25x12x3-Civic-Supra-S13-Mustang_W0QQcmdZViewItemQQ_trkparmsZQ7c301Q3a0Q7c293Q3a2Q7c294Q3a30QQ_trksidZp4634Q2ec0Q2em14Q2el1262QQhashZitem3a4fc11a3aQQitemZ250446158394QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories


Thanks Dan!
With shipping those would all be well over $100 US especially to me in Canada. I could get a DSM intercooler for very very cheap.
But i like those ones. Which would you think would be best? the third one i dont think would fit... The second one looks alright but it's quite small. The first one? :D


Uhhh, so i went with the smallest, cheapest one... and they list the price as $47 + shipping/handling... and the total was $142 USD + taxes and duty... So i said screw that.
Title: Re: My much anticipated 1.6td/aaz head.
Post by: barrygti on July 06, 2009, 03:03:17 am
For what it's worth;
with that much extension of my exhaust  from the down pipe i've noticed EGT's to be about 200 degrees hotter on average. 120km/hr in 5th is at about 750F. My hill climb course (The Highlands from the bottom of McKee for those Abbotsford guys on here!) it will climb to 1,200F and just sort of sit... never gone higher than 1,250F

Just some insentive to have dual 2.5 inch ahahhaha i have 2.5 inch exhaust to the cross member then from there it is two 2.5 pipes. I dont feel like doing the math but it's pretty free flowing. On start up the only issue is that its TOO free flowing and it's rather loud (popping sounds as air pockets get stuck) but once it idles for about 20 seconds or i start driving it goes away. It can really make driving feel weird :P

Pictures of that exhaust please!!!  ;D
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on July 06, 2009, 07:58:30 pm
For what it's worth;
with that much extension of my exhaust  from the down pipe i've noticed EGT's to be about 200 degrees hotter on average. 120km/hr in 5th is at about 750F. My hill climb course (The Highlands from the bottom of McKee for those Abbotsford guys on here!) it will climb to 1,200F and just sort of sit... never gone higher than 1,250F

Just some insentive to have dual 2.5 inch ahahhaha i have 2.5 inch exhaust to the cross member then from there it is two 2.5 pipes. I dont feel like doing the math but it's pretty free flowing. On start up the only issue is that its TOO free flowing and it's rather loud (popping sounds as air pockets get stuck) but once it idles for about 20 seconds or i start driving it goes away. It can really make driving feel weird :P

Pictures of that exhaust please!!!  ;D

 It's not pretty by ANY standard :P
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on July 06, 2009, 08:16:32 pm
To recap...
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7967.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7967.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7947.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7947.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7949.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7949.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7994.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7994.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7993.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7993.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7992.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7992.jpg)

All i have is my crappy phone so ... sorry.
Here is a bit on how my paint job is going.
The hood did not mist very well so i need to wet sand it down, add mineral spirits to the paint and try again. The gun im using also does not like to spray when it is not straight up and down. My keyboard is stuck in french which is being very annoying so this will end here.
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7991.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7991.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX7995.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX7995.jpg)
Fuel flap still needs to be wet sanded but it looks mighty fine for a first coat.
Itès raining now so painting will have to wait till next weekend.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: 8v-of-fury on July 07, 2009, 10:47:56 am
Ed, Very nice paint. I think i will take your advice and spray it.. rather then roll it on lol.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on July 08, 2009, 08:31:51 pm
yeah spraying is easy. you just need a few days.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 27, 2009, 06:59:12 am
I don't remember posting how my paint turned out ... anyways here it is in my original thread. [all pictures are of course thumbnails]
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX8034-1.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX8034-1.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX8033-1.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX8033-1.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX8032-1.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX8032-1.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX8030-1.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX8030-1.jpg)

Here is my intercooler in the bumper and plumbed up. Biggest power improvement ever. But that likely was built off of the bigger head and higher boost pressures.
(http://i49.photobucket.com/albums/f279/edmcclung/th_DSC06118.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=DSC06118.jpg)(http://i49.photobucket.com/albums/f279/edmcclung/th_DSC06116.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=DSC06116.jpg)
Yes, that is ABS plumbing pipe. No, it doesn't melt contrary to popular belief.

My new fan out of a Taurus
(http://i49.photobucket.com/albums/f279/edmcclung/th_DSC06030-1.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=DSC06030-1.jpg)

And this is a picture showing that the IC just hangs off the bumper. I had to modify the plastic front valence extensively to make it fit right ...
(http://i49.photobucket.com/albums/f279/edmcclung/th_SSPX8075.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=SSPX8075.jpg)

I got chrome tips for the exhaust too.
(http://i49.photobucket.com/albums/f279/edmcclung/th_DSC05947.jpg) (http://s49.photobucket.com/albums/f279/edmcclung/?action=view&current=DSC05947.jpg)
Oh, and im the cover girl for Colt 45. Yes, that's a fake candy grill...
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 27, 2009, 07:07:25 am
I'll post a driving, acceleration, highway driving, exhaust sound video if people show any kind of interest.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: theman53 on December 27, 2009, 11:58:18 am
one showing interest
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on December 28, 2009, 11:44:26 am
x2
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: peacedub on December 28, 2009, 01:33:00 pm
x3, so are you still using the Volvo intercooler? which car did you get it off
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 28, 2009, 03:21:11 pm
x3, so are you still using the Volvo intercooler? which car did you get it off

No, i bought one that has "EMUSA" stamped on it. It's all aluminum. I knew the fibre glass tanks of the volvo one wouldn't appreciate 20 psi.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: TurboJ on December 28, 2009, 03:38:25 pm
x4
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: rabbitman on December 28, 2009, 03:51:54 pm
X5.5, we always like to see videos of these ;D
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 28, 2009, 03:56:06 pm
This is my intercooler
I hope the link works...
Link (http://cgi.ebay.com/ebaymotors/EMUSA-INTERCOOLER-27x8-5x4-ACCORD-HONDA-CIVIC-FIT-CRX_W0QQcmdZViewItemQQhashZitem20aea9da88QQitemZ140369320584QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories)

those dimensions aren't REALLY correct... at least from my understanding anyways. its more like 8x27x3.5
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: peacedub on December 28, 2009, 04:46:55 pm
do you have a boost controller ? how do you turn the boost up to 20psi?
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 28, 2009, 10:55:50 pm
do you have a boost controller ? how do you turn the boost up to 20psi?
by NOT having a boost controller :P  ;)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on December 29, 2009, 11:19:07 am
im still using a volvo intercooler just fine, althought its about to be ditched. too restrictive for anything over 15 psi.

and i had a home made boost controller on my K24 and it would make 25 psi no problem. so either way, you can either not run one, and risk the chance of exploding your turbo, or you can make one for about $.25 and be good to go. i had none of the right parts required when i started building mine, but it still works wonderfully. i used bigger check valves, and stiffer springs and stuff.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 29, 2009, 03:56:55 pm
im still using a volvo intercooler just fine, althought its about to be ditched. too restrictive for anything over 15 psi.

and i had a home made boost controller on my K24 and it would make 25 psi no problem. so either way, you can either not run one, and risk the chance of exploding your turbo, or you can make one for about $.25 and be good to go. i had none of the right parts required when i started building mine, but it still works wonderfully. i used bigger check valves, and stiffer springs and stuff.

twenty five cents? Do explain! OH, and i think something ccontrols my boost somehow. It will never go over 22psi. Must have something to do with the waste gate me thinks.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on December 29, 2009, 04:22:30 pm
the wastegate is spring operated. they pop open eventually when the exhaust manifold pressure gets high enough. they are called "magic" wastegates. atleast thats what ive seen people call the gates on a K24 turbo. i bet if you put a tack holding your wastegate closed, you would probably hit almost 40 psi. josh (powered by spearco) claims to be running 44 psi spikes from his K24, and i imagine that his wastegate is screwed closed or something. cause the magic wastegates pop at about 25 psi from what ive been told.

as for the 25 cent boost controller, i bet theres no way i could build one like what i built that cheap. i had all the parts & solder & spring & check ball laying around. i just started throwing parts together, and when i was done, it actually controlled boost.

also, it said to use a .010 hole to bleed boost, but instead i used a .020 hole, probably even better for a diesel tho, cause most gas engines dont run 35 psi boost like most of us want to. probably better for regulating higher boost, my thoughts at least. and another thing, i didnt have a damn .010 drill bit. haha.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 29, 2009, 05:48:38 pm
lolz-me-arse-off at the part about the drill bit hahahaha
So you reckon I'll still grenade my turbo utilizing my magic waste gate?
I'll make a video, i just need to figure out how im going to fixate my camera inside the car... It would be really cool to have several cameras like in a rally race showing my feet, gear stick, speedo, rpm, front, gauges, rearview mirror and what have you.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on December 30, 2009, 05:52:05 pm
nah, i dont think it will commit suicide till atleast 30 psi boost or so, probably even higher than that tho. probably closer to 40 psi or something. i guess ive ran my turbo to within an inch of its life quite a few times, i guess they start to explode at 35 psi. mines done that lots of times, but i think it was from retarded timing, because i had half the power with 35 psi than i do now with 20 psi.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: RabbitJockey on December 30, 2009, 06:27:52 pm
hill folk sent pics of his down pipe with a huge hole in it from the turbine wheel shooting out, but that was on a tdi-m with a t3
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on December 30, 2009, 10:15:24 pm
That's an interesting comment about the retarded timing... i found i got much higher boost with retarded timing but less power... was a lot quieter though...
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: foxracer1 on December 30, 2009, 11:17:49 pm
When the timing is retarded it creates higher EGTs so it would produce more boost but may not make more HPs. Thats why its fun to have lots of gauges to stare at.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on December 31, 2009, 03:30:26 pm
That's an interesting comment about the retarded timing... i found i got much higher boost with retarded timing but less power... was a lot quieter though...

my rabbit had tons (almost twice as much) and tons of boost with retarded timing, but driving it was just that, retarded. it wouldnt smoke, it wouldnt get very good mileage, but it sure was fun pegging the 30 psi gauge at the glance of an eye. and like you said, it was quiet. quieter rattle from the engine, and a WAY quieter exhaust note. i put a muffler on when i still had retarded timing, then before i took my engine out of my rabbit, i cut the muffler off to donate to my GTI, and then i took it for one last drive before i broke 2 motor mounts and pulled the motor. that last drive i took it on, it was so ridiculously loud.. just a 2.5 inch straight pipe. i never remembered it being that loud. but that was also after i got the timing alot closer to spec. it starts so much easier being timed well.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on January 29, 2010, 03:33:12 pm
SO,

Since im going to be hopefully getting lots of pressure and CFM out of the holset idea... I should increase the break pressure of my injectors yes? they are supposed to be at 155 bar. but i dont have any way of checking that for my self. A shop just told me they were "ok"

Also, am i going over the limits of my engine with this idea?
I'm basically shoving tons of boost down it's throat and attempting to make it breathe as freely as possible to burn as much diesel as is present in the chamber.

I've put a fraction of the money into my engine as other people on here, ARB, Saurkraut, Dave (953Racer), Mike, ect.

The only ... safety catches i have on my engine are new rod bearings... and that's basically it. I can't think of anything else.
oh, and measures to keep the EGT down. IE big exhaust & ported head.
Am i just making a bomb of sorts?
Please let me know if you think this is a REALLY dumb idea.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Rabbit on Roids on January 29, 2010, 03:57:20 pm
i still think the T3 is too big to use with a compound setup.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on January 29, 2010, 04:40:12 pm
i still think the T3 is too big to use with a compound setup.

we'll just have to see. can be easily replaced if it doesn't work.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: RabbitJockey on January 29, 2010, 07:05:27 pm
what intake manifold do you plan on using?
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on January 29, 2010, 07:44:40 pm
I dunno?
The TDI ALH one?
What else would fit?
The only alternative i can think of is somehow ... making my own runners for the exhaust and getting someone to make me a plenum style intake.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: rallydiesel on January 29, 2010, 08:46:01 pm
That's why vnt turbos are so great. None of the headaches of matching compound turbos and plumbing issues.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on April 16, 2010, 11:54:08 pm
New Stuff! :D
(http://i49.photobucket.com/albums/f279/edmcclung/DSC06343.jpg)

I will undoubtably be asking what some of these gaskets and copper washer things are for in the very near future
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: 8v-of-fury on April 17, 2010, 01:59:09 pm
NOICE!
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on April 17, 2010, 09:26:18 pm
Heatercore just blew up inside my car today...
adding that to the list. sighhhhhh
and the appropriate hoses
siiiighhhh
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: macka on April 17, 2010, 09:34:13 pm
Heatercore just blew up inside my car today...
adding that to the list. sighhhhhh
and the appropriate hoses
siiiighhhh


geez you sound like my ex with all the sighing
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on April 17, 2010, 09:53:16 pm
the past 2 months have been the most expensive times for my car ever.
front suspension (still need rear augh)
heater core and hoses and supply line (mine is rusted to hell)
bearings for everything
seals for everything
gaskets for everything
a clutch and pressure plate...
it's been like ... $1,000 in the past 6 weeks
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: macka on April 17, 2010, 09:57:09 pm
well with older cars, you can expect at one point to have a lot of stuff fail.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: vanbcguy on April 18, 2010, 12:28:44 am
Jezebel just kicked my ass in that department too...

- Front motor mount + bracket
- PS pump
- Water pump
- Oil seals (IM shaft seal went and completely drained my engine)
- Tires
- Exhaust

All that in a week... sheesh!
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on April 18, 2010, 01:52:32 am
my dash is just a christmas tree of flashing and dimly lit lights now.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: macka on April 18, 2010, 12:15:45 pm
its called dub love  ;D
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: vixentd on April 19, 2010, 02:10:36 am
Phone valley autohouse with your serial number to see if you car is covered with a recall on the heater core.  There was no date for having the recall done. They may do it for free.

I still have to drop by and see that dub. I live over by the tennis bubble. 
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on April 19, 2010, 03:42:46 am
oh really!!! hahaha
well i already bought one. i bought it the day mine broke. i think i paid 36$
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 05, 2010, 04:12:33 am
Build self destructed due to re-use of con rod bolts.
(http://i49.photobucket.com/albums/f279/edmcclung/DSC06459.jpg)
(http://i49.photobucket.com/albums/f279/edmcclung/DSC06460.jpg)

DO NOT RE-USE CON ROD BOLTS
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: catlin_cava on May 06, 2010, 08:03:19 am
I'll help a little too Ed

DO NOT RE-USE CON ROD BOLTS
;D
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: theman53 on May 06, 2010, 08:33:44 am
I thought we were guessed out to the point of thinking it may have been the oil pressure. IM shaft/vac pump deal? Let us know Ed.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: burn_your_money on May 06, 2010, 12:51:17 pm
Looks very familiar to what happened to my brothers AAZ. I didn't really find anything wrong with it (other then the obvious) when I took it apart.

(http://img.photobucket.com/albums/v603/burnyourmoney/DSC07760-1.jpg)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: foxracer1 on May 07, 2010, 11:40:14 am
I reused mine? my problem was foreign objects in the intercooler.

What kind of RPMs did you rev to?
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 07, 2010, 02:37:20 pm
I reused mine? my problem was foreign objects in the intercooler.

What kind of RPMs did you rev to?

before it broke or when it broke?
before it broke it would see 70km/hr in 2nd gear. or 100 in third at the most (i dont have a tach)
those are only 10km/hr over the shift points on the speedo.

when it broke the rpms couldn't have been over 2,500.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: foxracer1 on May 08, 2010, 01:47:44 am
both i guess. which you answered thanks. just wondering
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: 53 willys on May 08, 2010, 11:52:59 am
that's a real bummer Ed...sorry for your troubles... :'(
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 08, 2010, 03:43:04 pm
Here is to hoping the aaz lasts longer :P and i don't forget/mess something up.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: macka on May 18, 2010, 11:05:35 pm
Here is to hoping the aaz lasts longer :P and i don't forget/mess something up.

Didja get the MAPP gas yet? I think we are going to be moving the short bus to Surrey or Langley tomorrow. If I get Saturday off I might be able to help get the exhaust turbine housing apart. I'll also bring some deep creep to see if we can get it freed without heat.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 18, 2010, 11:35:49 pm
Here is to hoping the aaz lasts longer :P and i don't forget/mess something up.

Didja get the MAPP gas yet? I think we are going to be moving the short bus to Surrey or Langley tomorrow. If I get Saturday off I might be able to help get the exhaust turbine housing apart. I'll also bring some deep creep to see if we can get it freed without heat.

I spent the whole day painting the house. Didn't get the MAPP gas.
Sweet deal! let me know if you do.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 26, 2010, 12:07:29 am
Upon complete and total inspection of the crank, rods and IM shaft (what's left of it) the issue was that the IM shaft had siezed in place starving the two middle rods of oil and ultimately causing the rod cap to crack in the middle of the cap...

I found the cap split in two with the con rod bolts still in them...
the IM shaft bearing had almost nothing left. i found a bearing that resembled aluminum foil.
The metal sieve on the pick up of the oil pump saved the rest of the parts (ie. the oil pump it's self) from being destroyed.

a VERY strong neodynium magnet is a must have in your oil pan in my opinion. Several even. not just one...

its the cheapest and easiest extender of engine longevity.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: 8v-of-fury on May 26, 2010, 09:25:21 am
This is crazy news.

Would the neodymium magnet (also known as Nd2Fe14B) be strong enough to hold the bigger chunks, that are still small enough to get sucked in to the oil pump? I have seen first hand accounts it is strong enough to hold shavings in the oil filter, but i dunno about chunks.. ?
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 26, 2010, 08:02:26 pm
a VERY strong neodynium magnet is a must have in your oil pan in my opinion. Several even. not just one...

its the cheapest and easiest extender of engine longevity.

None of the bearing material (99%? of the metal that is normally in engine oil) is ferrous and so a magnet in the engine oil will not do much to prevent normal wear and tear.

I agree but when those bits (the bearing material) enters the oil you want to get it out as quick as you can. im not suggesting that putting magnets in your oil pan prevents metal on metal contact...

None of the bearing material (99%? of the metal that is normally in engine oil) is ferrous and so a magnet in the engine oil will not do much to prevent normal wear and tear.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: theman53 on May 26, 2010, 08:10:32 pm
I think what he is saying is the bearings are mostly lead. Not magnetic. The magnet is a good idea, as it gets the hard stuff. The lead is so soft I would hope it doesn't do much and then gets trapped by the filter.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 26, 2010, 08:19:10 pm
I think what he is saying is the bearings are mostly lead. Not magnetic. The magnet is a good idea, as it gets the hard stuff. The lead is so soft I would hope it doesn't do much and then gets trapped by the filter.

OHHHHHHH I gotchya. I never thought of that. I thought bearings were tin. Shows what i know :P
got the last of my parts today for my new build and Tyler found a company that would ship me his aaz block.

I never realized this but the 1.6td blocks have the port for a crank venting system. I wish i had known that years ago...
Also, anyone reading this who knows of a good place to order a Garrett T3 rebuild kit please let me know. I have a site for a local place that will do one for about $75.
http://www.adpdistributors.com/turbochargers.html (http://www.adpdistributors.com/turbochargers.html)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 26, 2010, 08:22:34 pm
Upon further consideration, changing the IM shaft bearings is about on par with importance as a proper timing belt tensioner and new timing belt... for without new ones you totally trash the engine...

Anyone reading this, i would totally reccomend changing the IM shaft bearings. You can do it in car - there is no reason not to.

remove the vacuum pump & oil pump and the cover that holds the im shaft in place and i THINK it will slide out?
mine did anyways but mine was also in about 50 pieces. (it literally shattered. the largest piece is about 3 inches long.)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: theman53 on May 26, 2010, 09:07:52 pm
some may have tin, copper, lead, just something soft I think. I am not 100% certain, but I know it isn't hard. :D  except some of the backers are steel and are magnetic.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 26, 2010, 09:37:37 pm
There was definitely some loss of steel backing. the bearing was non-existent.
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: Smokey Eddy on May 27, 2010, 03:20:15 am
Yeah, the actual bearing surfaces are non-magnetic and so the only actual magnetic material during normal engine wear comes from the vac pump gear, rod thrust surfaces and cylinder/ring wear.  By the time you actual have any significant magnetic bits in the oil you've lost oil pressure and your engine is already done for.

Intermediate shaft bearings are the only bearings in these engines that typically fail.  I don't know if you can get the intermediate shaft out with the engine in place.

oooh i see. yeah i guess mine was forced out in several pieces then because once i removed the cover on the side of the block it slid right out (what was left of it)
Title: Re: My 1.6td/aaz head and other stuff too.
Post by: rabbitman on May 27, 2010, 03:17:32 pm
By the time you actual have any significant magnetic bits in the oil you've lost oil pressure and your engine is already done for.

That's funny 'cause piston engine aircraft ALWAYS have some metal in the oil screen, usually barely enough to find with a magnet but it's there. Most times there's excessive metal it's from the camshaft/lifters. I've always wondered why they made metal and cars don't? Maybe it's just because they run at a high power setting for lots longer.