My slow AAZ rebuild

[gnavs]

Thanks GB, I've been keeping an eye out for bare heads lately but still think I'm going to stick with the one I've got providing I don't render it unusable for some reason.

I got the entire rotating assembly in last night, so nice to see things coming back together.  Still need to clean up some parts, I've been putting it off because, frankly, it sucks cleaning 13 years worth of diesel crud off of everything. 
No pics right now, so you'll just have to trust me 

[GEE-BEE]

SET OF Three 1.9 AAZ COOLANT HOSES

95.00

5 ply silicone, one piece design

Color's:Black, blue , red, yellow

Dont let me be the only one with them.....

GB

[gnavs]

Sorry GB, I'd love them but funds are tight right now.  I ended up getting some stock replacement hoses but I still want a set of those silicon hoses eventually, they look amazing. 

And the reason I can't stop smiling today is apparent in these pictures.  Long story short, a friend of a friend is an amazing aluminum welder and for a case of beer he was able to help me out.

Before:



After:




Time to port the hell out of this sucker and check that everything is straight. 

Now, since I've got my valve guides out can I grind down some of the hump that the guide goes through?  I didn't really want to get too crazy in that area but I remember seeing someone (aki?) that had ground the hump and the guide down as well. 

[BAM]

Nice work   

[gnavs]

Good to have the forums back up and running again.  Here's some pics of recent progress.

September 14
Ported the head this past weekend, opened it up quite a bit actually.  I essentially gasket matched the head but there was a lot of material that needed to be removed for that to happen.  No pics at the moment but it was pretty straight forward.

Last night I got to reassembling the accessories and brackets. 




Aaaaand ran into a snag, the crank pulley I bought ended up breaking while trying to turn the crank.  I'm just glad this happened now and not while it was running.  3 guesses as to who this came from 


Major PITA but it doesn't really set me back too much since I still need to measure piston protrusion and order the right headgasket.

[gnavs]

September 15

$1.25 for this communist built tool, funny thing is it works better as a valve lapping tool than it does as an arrow.  Doesn't fly for sh!t.

[gnavs]

September 21

Painted some brackets and attached a few more things.  I can't for the life of me remember how the power steering pump attaches though  :oops:



Torqued down the head and slapped on my G60 valve cover, intake and exhaust manifolds just to see how it all looks.





Should be ready to time the thing soon.

[gnavs]

now serious question, does anyone have a picture of their power steering pump and how it attaches?  I looked through the Bentley and I'm pretty sure I'm not missing a bracket but I can't for the life of me remember how it all attaches.  I know it sits under the alternator but that's where I blank.

[theman53]

No idea on the Power Steering. I would like to see the A/C picture w/o power steering. It isn't in the serp thread that I remember.
Great looking work you have going there. Especially like your valve cover.

[gnavs]

Thanks Lucas, I've actually spent most of the day reading "power steering delete" threads and am seriously considering it (but not just because I can't figure out how to mount it!).  I'm sure I can handle un-assisted steering myself.  If I can do it on a tractor I can do it with this POS 

[theman53]

Yeah I don't know what year the car is. It looks mkiii but the mkii and mki that I have owned are easy to steer. Even my wife can park it with relative ease. Once it is rolling there is just little finger pressure to move the wheel. Good Luck.

[gnavs]

It's a MK3, so it'll be a bit heavier but I'm 99% sure I can handle it

[8v-of-fury]

it mounts under the spot for the A/c compressor. I think the bracketry is the same-ish for the TDI, I'll snap a picture for you.

Mounts with three bolts i believe too.

Driving a power rack without power will be tougher then the same car with a manual rack. The power rack has different ratios because it is ment to be power assisted.. gf's mk2 had a power steering failure (punctured line) and it was unreasonable for daily driving.. not overly too bad for her e and there whist blown.. but i wouldnt want to live with it

[gnavs]

Started to pimp my glowplugs, Vince's DIY is money! 


And an updated pic from last night


I'll need to figure out a tensioner setup for these belts now.  Without AC or power steering I might have to get creative.  I'm thinking I'd need something for both the water pump belt and the alternator belt.  I might be keeping an eye out for a non-ac alternator bracket but suggestions are certainly welcome at this point.

[gnavs]

I had a bunch of pictures from the last few weeks but they've mysteriously gone missing so here are a couple to bring everyone up to speed again.
Got the engine dropped in late last night so there is definitely light at the end of the tunnel.  Will start hooking lines back up today.