AAZ Turbodiesel swap into '86 Vanagon Syncro

91Transporter16" · Posted: Wed May 30, 2012 8:58 pm Post subject:

I'm going to be heading to a wrecking yard this weekend to look for these accel cable ball mounts. I'll grab several if I can. Tell be what diameter the socket is where the ball fits into. I have a 1.6td lever and it's to small. Can't figure it out. Mad

Syncroincity · Posted: Wed Jun 06, 2012 7:17 pm Post subject:

Time to eat a little crow... Razz

I failed to read the instructions regarding the BMW booster can; I didn't shorten the rod end.
I just put the OEM can back in for the time being. I was actually able to disassemble the pedal cluster enough to accomplish this without removing the dashboard again.
Once the skin grows back on my knuckles, I'll put everything back together and check the brakes w/ the motor running...
Have to bleed the clutch again, but my pressure bleeder makes that a matter of minutes. Cool

Best tool I've bought in a while.
_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

91Transporter16" · Posted: Fri Jun 08, 2012 7:40 am Post subject: Throttle Cable

Good to hear you didn't have to remove the dash. That's a huge job. I always try to stay with the original stuff to avoid these kind of problems.
Like my throttle cable problem.
I finally found a solution to make my OEM throttle cable work. I got a hold of these cable ball mount off of a BMW. Almost all of the ball mounts appear on German cars. VW Rabbits have them as well. I had to weld a ball mount on top of the original 1.6L lever to shorten the stroke. And I had to make a new cable mount in order to bring the cable closer to the lever on the pump.
It was a hassle but it worked.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Syncroincity · Posted: Fri Jun 08, 2012 5:14 pm Post subject:

Sweet! Nice fix. Smile

_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Syncroincity · Posted: Sun Jun 17, 2012 1:57 am Post subject:

OK, last weekend I dove into the belts looking to stop my oil leak.

Exhaust came off, and I ground and re-welded some of my previous beads, they were too small, with weak penetration.
I must say, having an auto-dimming helmet is THE way to go... picked up a used Speedglas on Ebay. A little pricey, but it has a huge window compared to the cheap ones, and the inner and outer shields are replaceable.

So back to the engine... Belts off, pulleys off, timing cover off, timing lock in on the pump, timing belt off. Now just as I'm persuading the intermediate shaft pulley off, I notice that the seal for it seems to be moving slightly. Got the pulley off, and yep, the two bolts holding the seal carrier to the block are only *kinda tight, not guten-tight. Ah-HAH, I think. It's wet below the seal, too. That's a bingo!
Cleaned it up, torqued the bolts, and etc etc installation is the reverse of what you just did...

Started up, and NO LEAKS! Smile

For about 2 minutes. Confused

Then it started dripping again. Crying or Very sad

And then it rained for two days straight. Image may have been reduced in size. Click image to view fullscreen.

So guess what I'm doing again this weekend?

I'm going to have a look at the crank pulley holder this time, and maybe slather everything with Great Stuff as well.

I'm getting pretty good with the timing belt, in any case. Wink

_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Andrew A. Libby · Posted: Sun Jun 17, 2012 9:27 am Post subject:

Change the 14mm galley plug that is right at the int shaft seal carrier. I have personally had THAT be the culprit. You can also pull the vacuum pump and drive the oil pump with a drill and see where it's leaking from.

Syncroincity · Posted: Sun Jun 17, 2012 7:16 pm Post subject:

I saw the plug, I'll double check it with the oil pressurised. Is this a commonly found size or do I need to go to VW to find a new one?

Didn't get anything done today, I was getting new tires on both of the other cars.
The Jetta got a set of Hankooks, the H725 Mileage Plus II, a new all-season that's been getting high marks from users.
I'm not a fan of all-season tires, but there's very little choice any more in 14" tires for summer tread.
185/65-14... one step undersize, but it looks ok on the OEM rims.
The Passat has been a good girl, and got a set of Michelin Pilot Super Sports, 225/45-17. Really sweet performance summer tire.
I got both sets from Discount Tire Direct dot com... a little plug here.
Free shipping, and the best prices I've found, and they price match.
I purchased the BFGs for the van from them as well. They also have a great, cheap (and optional) damage replacement plan.
Useful here in NY/NJ with roads that resemble the Appian Way in Rome.

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...no I take that back. Given that it's 2000 years old, the Roman road is in much better shape.
_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Zeitgeist 13 · Posted: Sun Jun 17, 2012 8:07 pm Post subject:

Since this thread is officially over one year old, Kitty and I have conspired to convene an intervention of sorts. We now give you exactly two weeks to have this van fully sorted and road-worthy. You have your mission, and success is in sight. Do not let Kitty down. Failure is not an option.

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_________________
--Casey
'89 Bluestar
"Endeavor to persevere"

Andrew A. Libby · Posted: Sun Jun 17, 2012 8:10 pm Post subject:

Syncroincity · Posted: Mon Jun 18, 2012 6:35 pm Post subject:

91Transporter16" · Posted: Tue Jun 19, 2012 7:36 pm Post subject:

Wow what a pain in the butt. I've had similar problems with not placing the seal in the bore correctly. I did this to a 1.8td and the seal lip folded over and leaked like a water hose on full blast. I had to jump into reverse to fix it with screams and throwing tools because we had a road trip the next day. I don't make that mistake again.
Like Libby said, I used a drill to prime the oil pump and it works really well.
Hope you get it on the road soon. Very Happy

Syncroincity · Posted: Tue Jun 19, 2012 8:15 pm Post subject:

Got it.

It was the intermediate seal housing, still leaking even after the re-torque. Not a drop from the galley plug, nor the crank seal.

I pulled the seal out, dried it out and doped it up with Great Stuff around the perimiter, making sure to leave the drain hole open. I also made sure the drain to the sump was clear and clean. Let it set for a while, then hit it with a few minutes with the drill, and it was high and dry; enough for me to begin reassembly. Put the timing belt back on, and started the motor with all the covers off, let it idle & warm up a bit, still no leaks. Finished reassembly, looks like she's good to go.
_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

91Transporter16" · Posted: Tue Jun 19, 2012 8:41 pm Post subject:

Good to know Jerry.
Now it's time for a spin around the block.
Let us know how it drives. Very Happy

Syncroincity · Posted: Thu Jun 21, 2012 12:11 am Post subject:

Boy, summer showed up with a vengeance... 90 degrees at 11AM. It was 115 actual in the Holland tunnel on my way to work tonight.

Needless to say, zero work got done on the van today; too busy breaking out the air conditioners and taking my hairy cat in to get shaved (poor little bastard gets all matted up every spring) so I'm done for the week. Might do a Cali trip next weekend, my 2-week timetable is suddenly looking grim. Razz

About all that's left is re-bleeding the brakes/clutch and straightening up the wiring in the engine compartment. I also need to pull the LED for the glow plug and reverse it; it turns off when the plugs are heating, then turns on the rest of the time. Embarassed

..oh, yeah, I also have to figure out what to do for crankcase ventilation. The intercooler on top of the valve cover precludes using the OEM plastic tube and hockey puck. I bought an old-style breather with the hose connection on it, but can't find the damn thing, I think I'll have to make one from flat AL stock, then run hoses from there and the valve cover to a breather/catch can, and maybe a "vacuum" line to the turbo inlet pipe.

This guy... the one displaying his junk to the world. Laughing

I'll post up the "After" pic tomorrow.
_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

91Transporter16" · Posted: Fri Jun 22, 2012 7:23 am Post subject:

I too have the same problem with the breather tube. We are going to make a Tee connection and plum it back to the intake. Not sure about the pressure affect coming from the turbo though. A catch can works but it pollutes too much I believe.
As long as the catch can has a return back to the intake.
Fortunately my DoKa has room for the intercooler so I can use the oem breather puck.
I have heard of lots of heat your way. Here it's been cool. 60s and 70s. Yesterday we hit 82 and to day 68.
Poor cat. A shave would help. But then his junk will show even more. Shocked

Syncroincity · Posted: Sat Jun 23, 2012 3:38 am Post subject:

Picked up one of these China-corp cans on Ebay. I'll take off the top filter and run a hose from that port to the intake on the pre-turbo side,
like the original AAZ rubber intake tube was set up. The other two "in" get hoses from the block and the valve cover.

Image may have been reduced in size. Click image to view fullscreen.

_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Syncroincity · Posted: Sun Jun 24, 2012 2:23 pm Post subject:

As promised, a picture of shaved puss...

Who needs Jenny Craig, he lost 10% of his body mass with a haircut.

Image may have been reduced in size. Click image to view fullscreen.

_________________
Jerry McCavitt
'86 Syncro Camper AAZ swap in work
'04 Passat Variant 4Mo 5MT
'98 Jetta Wolfie
Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

Zeitgeist 13 · Posted: Sun Jun 24, 2012 2:45 pm Post subject:

Dear gawd, kitty and I did not bargain for this!!! Dignity is in full retreat

Image may have been reduced in size. Click image to view fullscreen.

_________________
--Casey
'89 Bluestar
"Endeavor to persevere"

91Transporter16" · Posted: Mon Jun 25, 2012 7:58 am Post subject:

HA HA!! He looks disgusted. But much cooler I bet. Laughing

MidwestDrifter · Posted: Mon Jun 25, 2012 8:29 am Post subject:

Its 106 degrees here today. May have break out the trimmer for my cat as well...

I am glad you decided to do a proper crankcase vent. To many ppl just toss a filter on there and call it a day...
_________________
1982 Diesel Westy W/ ABA I4 hybrid
Epic Road Tripping since 08/05/12
http://drivechuckdrive.blogspot.com/

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AAZ Turbodiesel swap into '86 Vanagon Syncro
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