Hi all,
I've got an AAZ motor that I am preparing to drop in my 1982 vanagon. I've been doing body work on the van, so I'm taking my time with the motor.
I'll post pictures later. I don't have them on this computer.
I bought the motor from a Canadian member of this forum, who has been helpful and gave me a very reasonable deal. (thanks Rob)
The first thing that I did was take off all accessories, brackets, etc., so that I could clean and remove rust, and then paint the block. That's done, and I've been putting it back together slowly.
I bought a new oil pump, timing belt and tensioner, gaskets, rear crank seal, and other odd and ends.
I have a lot of questions about what I ought to check / do to this motor before I put it in. Thanks in advance for whatever help you can give me.
The head was recently rebuilt.
I have removed the pan and checked with feeler gauges a few of the tolerances listed in my vanagon 1.6d Bentley, and they seemed reasonably close to those, but I don't know how different the aaz might be in these respects.
I'm just learning about this motor.
Here are some questions:
What should I check in the block? Where might I stick a feeler or dial gauge? Should I do any dis-assembly?
The 'tab' at the end of the oil pump shaft is very worn (i'll post a picture later). Might what that hooks into on the vac pump be worn also?
Is there anything that would be easy and prudent to replace while the motor is out and the oil pan is off, etc?
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I will be using a v-belt set-up, with only an alt and w-pump. The crank pulley didn't 'feel' wobbly or anything. How important is it that I take off the pulley for inspection, considering that I won't be using the sep belt?
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Unfortunately, any of the tapped holes in the block which were not filled with bolts are filled with rust, and I need three of these rusty holes for one of the vanagon motor mounts. I've been thinking about drilling and tapping the hole, installing a stud, and then using a nut rather than a bolt on the mount. If I use a stud that's the same size on both sides, that might mean drilling out the holes in the mount so that the stud, which will be larger than the original bolt, will fit.
Any suggestions?
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The k03 turbo has axial play. I measured it with a dial gauge, and it's quite far out of spec. I'm thinking about: a) running it for awhile anyway b) rebuilding it myself using one of the available kits c) paying to get it rebuilt or d) getting a different turbo
I'm especially interested in rebuilding it myself. thoughts?
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I have two different intake manifolds. Unfortunately, both have the oval, 1.6td ports, rather than the aaz d-ports. I'm thinking about using one of the oval-port intakes for awhile, and then later getting an aaz intake. Thoughts about that?
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I have a mig welder, and intend to make some kind of exhaust myself. But, I've had a little trouble locating a k03 006 downpipe flange, or a downpipe that I can hack up. Prothe sells a whole downpipe for $60 ! I'm considering it. thoughts? Z&S imports sells just the flange for $60. It looks nice, but I don't trust them.
I was given a drill press recently. I've been thinking about using it to try to make my own flange!
Excuse the long post! thanks for the help!! I'll post some pictures soon