Thezorn's AAZ rebuild.

[Thezorn]

A while ago the crank nose sprocket stripped on me in my 93 AAZ. I decided to go the cheap and easy ways and just file the crank and replace the sprocket.

Well, it finally has come to bit me in the but. Today while I was at work my girlfriend was driving and it died on her. I immiediately asked her what was happening; white smoke, wont idle, rumbles the whole car, smells terrible. I knew what happend.

This time it will get done right with the TDI sprocket and im guessing I will have to re-do the head.

Anyways I will start tearing it apart as soon as I have more then one day a week off and work less then 12 hours everyday. Ill post pics when I can too.

Just thought I'd share that

-Will

[vako]

were you using  standard serp belt setup?  i am planning on doing the same thing. so im curious for how long did your crank nose last. but i'm using vitara belt pulley(without harmonic balancer), which is not as heavy as aaz harmonic balancer.... and i think crank nose will last longer 

[GEE-BEE]

Clutch pulley installed ?

Time to port and polish the head while it's out

I have a extra head if needed, used

GB

[Thezorn]

It lasted about 6 months, and I actually just re-torqued/made sure it was still tight a week and a half previous to this. So that just proves that it will choose to go when it wants to. Im definatley recomending doing the TDI sprocket swap (wich I should have done in the first place).

Yes it is the serpentine set-up with the huge pully/harmonic balancer thing.

As for the head im sure its fine it was actually just dropping back down to an idle when coming to a stop in second gear when it slipped so im hoping no bent valves, but when its all apart I will see. And as for P&P of the head, I personally have no idea how to do that well, but when the time comes ill see what I can do.

[jpedro]

oh no thats horrible i just seen you two driving it the other day to. uggghh.  well when ever youre doin some work give me a shout if youd like a hand. almost guaranted theres bent valves if it put your timming out any little bit remember i learnt the hard way to. but yea gimma a shout. time to upgrade to that k24 at the same time :p not sure if much is compatible of that extra motor i got sitting there but let me know .

[Mark(The Miser)UK]

So, you think that the pulley has slipped, and done some damage, maybe bent valves etc, but only slight [hopefully as it was near idle]. It then ran rough, so  at least some of the valves are operating on some of the cylinders.
So my question is:
How can it run and, [assuming the timing can't correct itself], not clash with the other valves, and bring all cylinders into non operation, without you resetting the pulley?Or have you?

Maybe it is some other problem

[gldgti]

depending on the clearances, not all the valves may be badly damaged. some will be worse than others.

I have a 1.6 hydro engine i picked up second hand with a wrecked crank nose (it was an industrial engine). when i pulled the head apart, I found 2 exhaust valves badly bent, 1 more just a little bent and 1 fine.

[Vincent Waldon]

Yes it is the serpentine set-up with the huge pully/harmonic balancer thing.

Solid alternator pulley or clutched?

[Mark(The Miser)UK]

depending on the clearances, not all the valves may be badly damaged. some will be worse than others.

I have a 1.6 hydro engine i picked up second hand with a wrecked crank nose (it was an industrial engine). when i pulled the head apart, I found 2 exhaust valves badly bent, 1 more just a little bent and 1 fine.

Interesting, but does that explain a running engine? If your engine stopped after the disasterous event, then the state of your valves can be explained...
Problem occured, then first two valves were hit glancing blows and the pistons travelled past, and then came to a halt at valve  number 3, bending it slightly. The engine never reached  the final valve set.  Eg  in the sequence 1342, does the damage fit?

Due to an over zealous headskim, my engine has had a knock for more than 2 years

 Turns out it was exhaust valves... Other than cosmetic piston damage which is not as bad as it looks [only a couple of thou deep], no issues with valves.

[Thezorn]

oh no thats horrible i just seen you two driving it the other day to. uggghh.  well when ever youre doin some work give me a shout if youd like a hand. almost guaranted theres bent valves if it put your timming out any little bit remember i learnt the hard way to. but yea gimma a shout. time to upgrade to that k24 at the same time :p not sure if much is compatible of that extra motor i got sitting there but let me know .

Im getting it towed to my house tonight and ill probabley start tearing it apart tomorrow or saturday.

So, you think that the pulley has slipped, and done some damage, maybe bent valves etc, but only slight [hopefully as it was near idle]. It then ran rough, so  at least some of the valves are operating on some of the cylinders.
So my question is:
How can it run and, [assuming the timing can't correct itself], not clash with the other valves, and bring all cylinders into non operation, without you resetting the pulley?Or have you?

Maybe it is some other problem

I dont really know what your getting at. But, I do know the pulley slipped since my timming is out. WAY OUT
Just to clearify this did happen once before and I just put a new pulley on the crank and reset the timing. and now it has slipped again.
and after this happend it didnt "run" it pretty much just made a bunch of noise when I tryed to turn it over when I got home, then I checked the timing, and saw what had happend.

Yes it is the serpentine set-up with the huge pully/harmonic balancer thing.

Solid alternator pulley or clutched?

I beleive it is solid, but then again I dont really know the difference between the two

[Mark(The Miser)UK]

I dont really know what your getting at. But, I do know the pulley slipped since my timming is out. WAY OUT
Just to clearify this did happen once before and I just put a new pulley on the crank and reset the timing. and now it has slipped again.
and after this happend it didnt "run" it pretty much just made a bunch of noise when I tryed to turn it over when I got home, then I checked the timing, and saw what had happend.


Sorry I didn't get from your first post that the timing was definitely way out. I just thought you were guessing, and referring to what had happened previously.
I also didn't know that you had tried to restart it. I took it, that it actually had ran afterwards, all be it terribly, and wouldn't idle properly.
My mistake. Fingers crossed that problem is not too expensive

[Thezorn]

Car was towed to my house last night and I will hopefully be beggining to tear it apart this weekend.

Working 10 hour days  6 days a week isnt very convinient at the moment

[Thezorn]

Ive been slowley pulling the car apart with the 2 hours a day I have off between getting home from work and going to bed. Sorry no pic at the moment, Ill try and get some up tomorrow if I have time. Engine will come out either tomorrow or sunday, then I will start pulling it apart.
Hopefully some time off will come soon
and this negative 10 degree wind chill will leave

I do have one question, when I was taking the line off the vacumm pump that goes to the master cylinder, the part that it connects to the vacumm pump broke off, its the little white rubber maybe plastic? piece. Ill post a picture tomorrow, I dont know if this really makes sence, but.....how screwed am I? Im guessing it wont be cheap

[Thezorn]

Finally have time to post on here, The engine is out and apart just have to take the crank and pistons out then it goes off to the machine shop maybe tomorrow. Ill post tones of the pics Ive taken tonight throught the engine coming out.

Almost all the parts Im gunna need are on order, going to have to see what the machine shop says, on wether ill need a bore and new pistons or if they can just clean it and re cross hatch the cylinders. Ordered the arp hardware last night now I just need to order the clutch disk and pressure plate. What is everyone else runing so I know my options?

[Thezorn]

Fianlly pictures!

Everything was stripped off and ready to go



On the top of the vacumm booster. Is this some sort of check valve?







the head looks to be in really good condition, besides the usually small cracks between the valves.




Cam is in very good condition, and no abnormall wear on the lifter.



Finally got the enigine out. Had to separted it from the transmition since I couldnt find a triple square bit for the cv axle flage bolts.


Everything is actually cleaner then I thought it would be. Is all the grim on the intake valves normall? from the CCV oil recirculation


Ill get more pics of the cylinders and the bottom of the head as soon as the camera battery charges.