My slow AAZ rebuild

[gnavs]

You're exactly right!  I read Vince's walkthrough regarding the dynamic oil pressure system and that's what I gathered from it.  I've hooked up my gauges anyways to be 100% positive so I'll likely be doing another test run tonight.  My phone's video capabilities are subpar so I'll have to find someone to act as camera-guy.  Hopefully I'll get some videos up soon.

[baldone]

I wait the video

[gnavs]

So I took the car for a trip around the block, after waiting for a few minutes for the coolant to get up to operating temperature, and had to shut things down due to an issue. 
At startup I was seeing around 50 psi oil pressure (sender mounted on the filter flange), dropping to around 25 when warmed up.  I got 3/4 of the way around the block when the pressure suddenly dropped immediately followed by a bad high pitched noise.  I shut it down and pushed it the half block home.  I was maybe seeing 2700 rpms during this trip so it wasn't revved too high. 
Initial reaction is intermediate bearings, or possibly the turbo, both of which were replaced during the rebuild.
Haven't tried starting it up again until I get some thoughts from you guys. 
Any help is appreciated.

[gnavs]

Bump
I'm gone for the weekend so hopefully there are a great many replies when I get back on Sunday 

[vanbcguy]

Make sure the intermediate shaft turns easily.

^^^^ Good advice... If it's binding then it'll slip on the t-belt and probably cause some freaky noises.  Vac pump can cause it to seize too!

[gnavs]

well the intermediate shaft turns with the starter and the vac pump doesn't seem to be seized either.  Everything seems to be spinning freely.
I guess the next step is to drop the pan and check my main caps/bearings...

[gnavs]

So the car has been moved to Rocky Mountain House at my good friends parents place.  I'll have access to a lift as well as old man mechanic knowledge.  My pops came down yesterday and hauled it back for me.  Some would call it progress, sorta.  At least it's not on the street anymore.

[vanbcguy]

So the car has been moved to Rocky Mountain House at my good friends parents place.  I'll have access to a lift as well as old man mechanic knowledge.  My pops came down yesterday and hauled it back for me.  Some would call it progress, sorta.  At least it's not on the street anymore.

What's with the straps on the mirrors? 

[gnavs]

it's obviously the strongest tie down point

[gnavs]

Well, progress made once again.  The loss of oil pressure was likely due to sludge buildup in the oil filter.  I make sure to always use Mann filters for this car and it may have been a combination of sludgy oil and/or faulty bypass valve in the filter.  I installed a cheap one from Canadian Tire for testing purposes and hooked up a pressure gauge directly to the filter flange (in place of the pressure sender) so I could monitor the pressure at the source.  I'm now seeing roughly 18psi at idle and 25psi at 2000rpm, which my mechanic friend tells me is to be expected with this engine. 
Either way I'm glad it was a filter issue and not something internal.  The thing purrs like a kitten again now.
I'll be heading back up to work on it again in the next few weeks so I hope to snap some more pics and get a video of it running.

[CrazyAndy]

Well, progress made once again.  The loss of oil pressure was likely due to sludge buildup in the oil filter.  I make sure to always use Mann filters for this car and it may have been a combination of sludgy oil and/or faulty bypass valve in the filter.  I installed a cheap one from Canadian Tire for testing purposes and hooked up a pressure gauge directly to the filter flange (in place of the pressure sender) so I could monitor the pressure at the source.  I'm now seeing roughly 18psi at idle and 25psi at 2000rpm, which my mechanic friend tells me is to be expected with this engine. 
Either way I'm glad it was a filter issue and not something internal.  The thing purrs like a kitten again now.
I'll be heading back up to work on it again in the next few weeks so I hope to snap some more pics and get a video of it running.

YAAAAY!  Another AAZ runs again!  Hopefully mine will join that list in the next few weeks/months. 

Went back and read all the thread; sure was quite the trip to get it back up from, what was it, 2010?  No matter how long it's always a great feeling when a long project nears the end; think of how it will feel when finally back at full DD status!

And you should totally throw those Porsche dials back on if you still have them. 

[gnavs]

Thanks for the kind reply!
It certainly has been a long time in the works.  This build has survived forum changes (not just vwdiesel), job loss, loss of interest and more so I'm glad to be at the point where it's just minor kinks that need to be worked out.
I got word from my buddy who's currently housing this lump that he took it for a drive last night.  I'm heading up there Saturday morning to do a bit more tinkering and possibly take it for a spin myself. 
Can't wait to get behind the wheel of this thing now, I really hope to be near the 150hp mark but we'll see.

[gnavs]

So here's a nice little video of it at idle.
http://www.youtube.com/watch?v=swsb40nVKYo

Also, the hood decided to fly up at me at 90km/h, must not have latched it well enough.  The hunt is on for a new hood, which shouldn't be a problem.  The thing is I was half expecting something in the engine bay to fail so the hood really surprised me.  The GF didn't appreciate it either  

[gnavs]

2 years later and I've decided to move this in a new direction.  I've been without a garage since 2012 and just didn't have the time or space to work on it, so it basically sat at my dad's farm getting rusty and full of insects.
Last weekend we decided it was time to remove what was important and scrap the rest.  The motor will live on a pallet until I can jam it in a suitable MK1.  That's the new plan 



The Jetta followed my too-far-gone old Rabbit to the crusher.  Scored $207 

[CrazyAndy]

Ooh that's rough to watch.  At least the engine will go on into a mk1 like mine.  Was the engine running good when parked? Too bad the Mk3 got crushed; I got a Mk3 TDI 8 months ago and am always looking for non-US interior bits.  Any leads on a good Mk1 swap shell yet?