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Engine Specific Info and Questions => IDI Engine => Topic started by: hodgy_7 on August 09, 2010, 11:31:26 am
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hello again i havnt posted for a while as my car has been sat for months and months but i finaly got motivated and started taking it apart.
after taking it apart i have found the usual cracks between the valves and if there is suposed to be a locating pin on the cam pully it isnt there any more..oh and very slight contact marks on 2 and 3 pistons 2 being a little worse than 3.
i will be taking the crank pully off soon for an inspection.
the other thing was i couldnt seem to line up the tdc mark on the fly wheel every time it came around the pump and cam were equaly out of place.(pump and cam were in sync as locked with the tools) so it looks like the timing was out by about 10 teeth but surely this would cause more damage than a little mark.
any advice on the situation. is it worth getting the cracks welded in the head.
also my brother has a spare 1z engine. what bits could(should) i borrow ;D off that for my aaz rebuild. will the cam pully go on my aaz.
thanks
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Sounds like the crank pulley either spun or the belt jumped. There is no keyway or pin on the cam or cam pulley, no worries nothing missing. The head should be inspected for bent valves, guides, damaged lifters, cam shaft damage. Put a new timing belt and tensioner when reassembling. Inspect the crank and pulley very carefully as it one of the weak spots on a AAZ engine. Pictures say a thousand words. Show us what you are working with.
There are some parts that interchange between the two engines please be more specific what you have in mind.
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thanks for the reply i will try and get some pics up tomorow (when i figure out how to)
so there is no pin or key in the cam pulley . well thats good news. i thaught there was something missing because at the top of the tapered end where the pulley goes on there is a cut out which looks like a key or locating pin should go . at least i dont need to find new pulley now.
as for the 1z parts it was just a general question on what i should take off and put on mine.
intercooler
alternator
would the turbo on a 1z be any better than the T2 on mine
also would it be best just getting the crank nose macheined to fit the D crank pulley or would it be better to put the whole 1z crank in.
i have a few more questions but i will wait untill i get some pics uploaded as you said picture paints a thousand words.
thanks
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here are afew pics
digging out the engine
(http://i599.photobucket.com/albums/tt74/hodgy_7/ventosaurus/Image0206.jpg)
kind of in one bit
(http://i599.photobucket.com/albums/tt74/hodgy_7/05082010073.jpg)
slight contact
(http://i599.photobucket.com/albums/tt74/hodgy_7/10082010098.jpg)
(http://i599.photobucket.com/albums/tt74/hodgy_7/10082010099.jpg)
(http://i599.photobucket.com/albums/tt74/hodgy_7/10082010096.jpg)
(http://i599.photobucket.com/albums/tt74/hodgy_7/09082010081.jpg)
(http://i599.photobucket.com/albums/tt74/hodgy_7/hingething.jpg)
as i was cleaning bits i sqirted some cleaner in the turbo bit and before it evepourated the liquid dripped out of the bit that is circled. i imagine if liquid can get out then exhaust gas can escape aswell (may be why i used to feel like i was getting gassed when driving it )
is this a problem if so how do i resolve it. (disconect the rod and weld it up ;D)
oh and here is a video of how the car ran before the engine was removed
vw vento 1.9 td smoke (http://www.youtube.com/watch?v=XfGjOfxW7JA#)
not great quality but you get the idea. also it would run smokey exactly like when it first starts. (hot or cold) unless the coldstart was pulled out.
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that thing you got circled is the wastegate.
it may leak a little oil, but it really doesnt leak much exhaust. if it were a big source of exhaust, there would be black smears all over around it..
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i wasnt actualy gonna weld it up. but i dont think if it was stuck shut it would be that bad would it ? obviously it will make the turbo work harder as it would be boosting longer. but im not an expert so i should stop thinking
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thats probably a T2, k03 or k14, none of them make much boost. and pretty much need wastegates. i wouldnt want a little turbo like that to over spool and send flaming chunks of compressor wheel down the intake.. a boost controller is the proper way to regulate the boost and make a turbo spool quicker. your wastegate functions right? give it a shot of aero-kroil if its stuck. then grab it with some vice-grips and work it around. it will free up.
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yip its a t2.. and the waste gate works well it opens if i push the lever. ill just leave that alone then. ill concerntrate on getting boost after i get the engine back together.
what would be a good upgrade for a t2 that would fit without to much work. also im planning to fit a intercooler from a 1z engine
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those T2's have the same trapezoid flange like a VW T3 right? if its the same as a K14/24/T3, i would just swap a K24 or T3 on there..
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Hi all back again... i have a few questions again
i have deemed the original aaz engine dead (un economical repair) as 3 out of 4 pots need re boaring or what ever.
any way
i sourced another aaz cheep in a 97golf which confused me as i thaught they stopped putting them in around 95ish.... it starts it runs no smoke (yet)hehe BUT it is the slightly more modern aaz it looks like a kind of aaz 1z crossbreed. and has wires going to the pump, which the old one doesnt
question is can i just swop the injection pump from the old one over on to the new engine
change the manifold and what not as new one has egr and that. then put it back in the old vento and start to get it back to polluting the atmospheer in style
any advice on what to swop what to keep would be greatly apreciated.
thanks in advance
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Yes you can swap the pump and manifolds. You likely will need to swap pump mounting brackets as well but that is no big deal. Some guys apparently just run with those pump wires unhooked and do just fine.
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thanks i was wondering if i could just leave the wires off but wasnt sure. i might just put the engine in without swoping the pump and see how it goes. i can always change it later if it doesnt work
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hi again peeps
Iam still no further forward with this car. but i intend on working on it next week.
could any one tell me which turbo would be the best to use the new one has a k03 and the old one is a t2 should i just leave the k03 on and blank the egr or swop it out for the t2
thanks
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hi again peeps
Iam still no further forward with this car. but i intend on working on it next week.
could any one tell me which turbo would be the best to use the new one has a k03 and the old one is a t2 should i just leave the k03 on and blank the egr or swop it out for the t2
thanks
neither turbo is really BETTER than the other..
they both spool early, and run out of breath before the engine does..
the T2 should be a little more boost friendly tho.. 15-20 psi max is all i would ever go with a little turbo like that..
i just swapped a K24 turbo on my TD, and i LOVE it.. spools nice and low, prolly not as low as a K03/T2 tho, but ive never driven an IDI with one of those turbos to know how it performs.. i do know that i LOVE the way my K24 performs with the wastegate unhooked tho.. they have MAGIC wastegates.. leave them unhooked, and they POP open from exhaust drive pressure at around 25psi.. works nicely actually.. the K24/T3 turbos spool nice, and there good for lots of boost.. 30+psi is easy from a K24 or T3 turbo.. good for making power on the top end..
anyways, hope some of what i said helps out..
what are you trying to accomplish with your car? something quick that has instant boost when you stomp on the GO pedal? or a car that has soft bottom end power, and then starts burning the tires once boost hits? my car is the latter of those 2 options.. the bottom end power is soft, but once the turbo lites off, hang on, and start shifting!!
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i just swapped a K24 turbo on my TD, and i LOVE it.. spools nice and low, prolly not as low as a K03/T2 tho, but ive never driven an IDI with one of those turbos to know how it performs.. i do know that i LOVE the way my K24 performs with the wastegate unhooked tho.. they have MAGIC wastegates.. leave them unhooked, and they POP open from exhaust drive pressure at around 25psi.. works nicely actually.. the K24/T3 turbos spool nice, and there good for lots of boost.. 30+psi is easy from a K24 or T3 turbo.. good for making power on the top end..
Now THAT I didn't know about K24 wastegates; is it safe? Does that cause too much spike or is it quite an even spool to max boost? Either way I know what I'll be doing with mine when I get it. 8)
Heard so many good things about the K24 it should be called the 'Jesus turbo'. :P
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i just swapped a K24 turbo on my TD, and i LOVE it.. spools nice and low, prolly not as low as a K03/T2 tho, but ive never driven an IDI with one of those turbos to know how it performs.. i do know that i LOVE the way my K24 performs with the wastegate unhooked tho.. they have MAGIC wastegates.. leave them unhooked, and they POP open from exhaust drive pressure at around 25psi.. works nicely actually.. the K24/T3 turbos spool nice, and there good for lots of boost.. 30+psi is easy from a K24 or T3 turbo.. good for making power on the top end..
Now THAT I didn't know about K24 wastegates; is it safe? Does that cause too much spike or is it quite an even spool to max boost? Either way I know what I'll be doing with mine when I get it. 8)
Heard so many good things about the K24 it should be called the 'Jesus turbo'. :P
working wastegates will pop open.. stuck wastegates will blow up the turbo..
and no spike that i can tell.. regulates boost fine..
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thanks for the reply i dont realy know what im trying to get out of it at the minute. probably would go for low down power i think.
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Hi again
Engine is finaly in. now for the problems.
1 the heater plugs dont work (well the light doesnt come on)
2 more importantly no fuel getting to injectors
is there anything i should be doing wiring wise as the new engine has the pump with the wires hanging out of it
where as the old engine had the manual cold start and all that on it,
everything seems to have just plugged in to the origional looms on the car so i dont know what to do. the pump is moving fuel as you can see it in the clear pipes but not getting to injectors
also in both my manuals the only pump it shows is the old one and says newer ones have self diagnostic something on.
please help
Thanks
Andrew
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Are you sure that your glow plug relay and fuse bar are good? Do the wires and plug boss have continuity and low resistance? If so to all of that, then maybe your glow plug lamp is inop, maybe a concern with the PCB on the cluster. EDIT just realized it's a vento, NVM.
AS for the pump, are you getting 12 volts to the fuel shutoff solenoid. If yes the are you sure that it is actuating? Might be a good idea to pull it out and see. Hopefully the pump hasn't got an internal fault. Crack an injector line and see if it's moving fuel out the lines if you haven't done that already.
Mind if we get a shot of the pump so we know what kind of plugs you are referring to? Also wouldn't it just be easier to put your other AAZ pump on this, assuming that you held on to it? I mean it worked correctly and didn't leak, right.
And my name's Andrew too! High fives! :D
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i will have a check with everything today. i was just wondering if there was somthing you had to wire up different with the newer pump. maybe the solenoid was on a diferent wire or what ever,
as for swoping the pumps thats beyond what i would be comfortable doing so would have to get some one else to do it they seem like a bit of a pain to get set up.
i just left the engine complete as it was running fine when i took it out of the golf all i changed was the turbo and inlet manifold.
i willl have a look today and report my findings
thanks
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looks like i forgot to report. the engine runs now has a lazy injector on start up but after this long im not complaning, the start problem was cured by smashing off the plastic box from the ip and direct wiring it to a ignition live. started up no smoke what so ever turned up the fuel screw a little still no smoke, i can see this engine needing a good tuning :P but i will just be happy driving the thing maybe next year. also if anyone is interested i have more or less every part from a aaz engine sat on a pallet so if any one needs anything give me a shout and i will try and sort something out. ;D
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Intercool that puppy, then turn up the boost. The AAZ has lots of room for improvement.