AAZ vanagon project thread

[zuhandenheit]

Hi All,

Thanks for your help so far! I've started a few threads in the last couple of days, but I have lots of little questions and don't want to flood the forum with new threads, so I'll post my progress and questions here.

This is the van, sort of put together:





Here's what I need to put in it:



I bought a motor that had a few missing odds and ends, and an AHU turbo and exhaust manifold. I also got an AC transmission, which has better gearing.

This project has been on hold for awhile, but over the last week I've been working hard to get this engine together.

At the moment I'm trying to figure out what to do with my AHU turbo and the AAZ manifold that I acquired (I posted about this in a separate thread), and am preparing to do the timing.

Right now, I have a problem with the timing belt cover.



I can't figure out what I'm doing wrong. The clip on the right is in the way of one of the IP bolts. I took all of this apart, so I know that it goes together somehow!

[libbydiesel]

There are two clips shown in your picture.  One is the clip to hold on the timing cover, the other is the nut for the injection pump bolt so it would make sense for it to be in the way. 

[zuhandenheit]

Hah, okay - thank you.

I must have mixed up some of the hardware from my old IP, because my bolt already has a nut on it, and this didn't look right to me.

[zuhandenheit]

I just looked at it again, and got it together - damn, I really should have been able to figure that out.

[GEE-BEE]

You will need my hose kit
http://www.thesamba.com/vw/classifieds/detail.php?id=1177342

I will include a set of front radiators as freebies for you
http://www.thesamba.com/vw/classifieds/detail.php?id=1199730

Good luck...

[Syncroincity]

GeeBee's hoses are top-notch products. 

That's a great-looking Westy, very nice! Some nice upgrades in the interior, too. Was it a diesel originally?

Have you figured out the turbo configuration yet? If you stick with a low-mount TDI manifold you'll need an adapter engine mount to go around it. Greaseworks sells a nice one, as do a few others, or it's a reasonably easy fab if you weld.

Keep up the good work, and keep posting pics!

[GEE-BEE]

Thanx Sync

I make the engine breather hose also...

GB

[zuhandenheit]

GeeBee's hoses are top-notch products.  

That's a great-looking Westy, very nice! Some nice upgrades in the interior, too. Was it a diesel originally?

Have you figured out the turbo configuration yet? If you stick with a low-mount TDI manifold you'll need an adapter engine mount to go around it. Greaseworks sells a nice one, as do a few others, or it's a reasonably easy fab if you weld.

Keep up the good work, and keep posting pics!

Thanks!

Yes, this is an 82 diesel. I had the great pleasure of driving it for a couple years with the original 1.6.  

I've decided to make an adapter plate for the turbo. I just ordered some 1/2" steel plate.

Today I finished prepping the transmission. The last thing to do was to fill it with gear oil. The fill bolt gave me hell. Here it is soaking in PB blaster:


This week I installed the flywheel and clutch on the crank, along with a new rear main seal, and a pilot bearing. I swapped the input shaft, bellhousing, and gear selector from my old transmission. I had a very loose 'oil slinger' in my bellhousing, a common problem which I discovered thanks to Andrew Libby, explained here:

http://www.thesamba.com/vw/forum/viewtopic.php?t=342440&start=0

My fix involved a lot of fussy spot welding, made much worse because I'm out of gas and stuck with flux-core wire. This is the sleeve, which is press-fit into the bellhousing:



I might time it next. Unfortunately, my IP timing tool doesn't fit my dial gauge. I'm working on a hack at the moment . . .

[zuhandenheit]

Thanx Sync

I make the engine breather hose also...

GB

You hoses look great. They're a little out of my budget, but would sure give me peace of mind. For the moment I'm afraid that I have to stick with original hoses . . .

[zuhandenheit]

I wasted too much time on my timing tool, but it should be straightened out now.

As I said, the adapter didn't fit my dial gauge. I probably should have just bought a new gauge, but instead I modified the adapter:







Sorry this is blurry. It turned out to be a pretty good fit. I don't even need the set screw.

[Gizmoman]

Very inventive - nice van by the way.

[zuhandenheit]

Thanks, Gizmoman!

I've just realized that I never figured out the oil plumbing for my turbo.

First, my engine didn't come with a feed line. I was thinking about getting a hydraulic shop to make something. I just saw this:

http://www.ebay.com/itm/Braided-Turbo-Feed-Line-Kit-VW-A3-B4-AHU-1Z-Replaces-Original-028145771BC-/221450265205?pt=Motors_Car_Truck_Parts_Accessories&hash=item338f76e275&vxp=mtr

Anyone know if the banjo bolt is the right size?

Any other suggestions for getting a feed line?

Second: I'd like to install the oil pump and oil pan, but I'm not sure yet if I'll need to modify the pan for an oil return line. It seems like the turbo will be positioned such that I could get a downward drain into the original connection on the block. Any thoughts? 

[Renax]

If running stock angle on the engine JX oil pan is the way to go, or the original 1.6 na with added oil return.
Use oilpump from AAZ, oilpickup from org engine. Also use the bolts from original engine as the aaz ones are longer and wont fit with the van's oil pickup...

You also should get a JX IP, the AAZ pump is to tall so you'll need to trim the engine cover to close it, and it will make it loud...

Sent from my cheapchinaphone using Tapatalk

[GEE-BEE]

Use firesleeve to protect the oil feed hose assy..

http://www.aircraftspruce.com/catalog/appages/fyrejacket12.php?clickkey=91156

Iam doing the same

I stock 1/4 and 5/8 i.d. if you need some

[libbydiesel]

I'd use a new diesel-vanagon oil pump.  They have the correct 36mm gears (same as the AAZ) with the correctly sized pressure relief valve.

I also wouldn't try to use a JX pump.  They are hen's teeth in the US and take JX specific injection lines which are somewhat rare and expensive in Europe and moreso here in the US.  The JX pump also has the wrong camplate for the AAZ and has a less tunable LDA than the typical TD injection pump.  Modifying the engine lid is very quick and easy and does if done in a reasonable manner does not add perceptibly to the engine noise.  Many of the AAZ pumps are also poor.  They have a joke LDA assembly with a very poor boost pin setup.  The best option, IMO, would be to use an AAZ pump with 1.6TD LDA top or similar.