AAZ- Once More, Into The Breach......

[Team WorldTour]

So, I have the engine stripped to the long block. The consensus in the workshop is 'oil starvation'.

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1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[MarkWard]

When I used to build VW inline engines, I would always prime them before the first start up. I had a simple rig for my drill.

I also found that you need to pay attention to new pumps with the clearance between the gears and the sump section. The last new pump had .007" clearance between the gears and the sump cover.

If reusing the sump, you need to verify the relief valve is not stuck. If all things are correct, there is no practical reason for an inline 4 to not have adequate oil pressure and volume. They have the opposite problem.
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☮️

[Team WorldTour]

I'm not reusing *anything*!
However, I've just opened the shipping crate for the new engine, and I'm not happy!
On the plus side, I now have an extra oil pan, oil pump, front and rear main seals.
There's *no* intermediate shaft!

The bushing is there, properly torqued down, just *no* shaft behind it!
WTMF?
Also, it's obvious to see, on the oil pan is just a paper gasket and not a windage tray.
Today is a German holiday, so I have to wait till tomorrow to call and complain.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Joy upon Joy!
It's Update Time!
Engine number three is a No-Go at this Station!
I was *almost* finished assembling it, when I discovered that one of the holes for the motor carrier was *off-center*!

This means that only two of the three bolts would fit!

Also, when they recut the threads, they did not cut them all the way down! Minus the motor carrier, the bolt would only thread 2\3s of the way down!
Using a depth gauge, the hole is half a centimeter deeper than the bolt is long.
Add to this, they charged me €200 to drill and tap the head to fit the JX valve cover, only to abandon the job halfway through!

So, as I pulled parts off the old motor, I noticed a few things not reported before. Oil in the exhaust.

Oil in the Turbo.

Broken glow plugs for cylinders 1 and 4.

And yes, the timing was still DNO.

Also, there is a noise in the old motor. See if you can hear it!

Link


So, here is where I stand.

I have two engines, both unsuitable\ unusable to send back for refund.
Now begins the search for another workshop to get an engine from!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[MarkWard]

That’s some bad luck for something that should be plug and play. Sorry.
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☮️

[?Waldo?]

I've probably said before but you might want to consider a 1Z, AHU, or AFN TDI engine and get an LT28 mechanical injection pump to run it. You'd want the engine complete with injectors, metal lines, pump bracket and timing covers. Everything else (intake, exhaust, mounts, etc...) would bolt up exactly the same as it does on the AAZ. The result would be increased performance, 15% better fuel economy, and increased reliability.

[Team WorldTour]

I think I might have to take you up on that....
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Do you have part numbers to help the search?
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Alaskaberrys]

Wow, that is some crummy stuff! My hats off to you preserving through this and I doubly appreciate this thread with the details.

What your going through does not have me looking forward to the day my AAZ acts up.....

Looking forward to hearing you have a running engine in Frank
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'91 Westfalia, Bordeaux Red Pearl 2.1L 2wd Auto
'91 T3 Syncro Doka, Escorial Green 1.9L TD AAZ “Gremian” (to provoke, irritate, exasperate, vex...)

[Zeitgeist 13]

I'm currently in the process of swapping out an AAZ in a Syncro for an AHU with a manual pump, so I can help with some of the gory deets.
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Team WorldTour]

[old_man]

The Land Rover 200/300 TDI pump should work in lieu of a LT28.

[?Waldo?]

Yes, the Land Rover 200/300 TDI pump might be more readily available. There are more gotchas to the install than the LT28 but it would work well. The main ones are:
-pump bracket needs to be machined to the larger pump snout diameter
-either the mounting bolts need to be slotted or the ALH sprocket/hub needs to be used

[Team WorldTour]

Thanks guzs!
Iäm on Holidaz for a week right now, Iäll have a look when I get back home!
)also on mz wifeäs computer. Sorrz for the spelling mistakes.=
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

It has taken *two weeks* for the motors to get picked up!
I've got the van back at the house now, because I don't have another motor ready to go, and the Base Commander now has a tow-happy bug up their ass!
Just this week the contract talks were finalized. Next week, towing begins! The Base Commander has the idea to tow ALL dead and unmoved cars next week.
No fucks given to where they are, in what condition, or anything. If they are in a parking spot, they are getting towed!
So, I just HAD to get the van out of there!
It looks as if I am going to be finishing this in my driveway now....
somehow!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[?Waldo?]

I've done several engine conversions on a dirt and river rock driveway. A garage with concrete slab and lift is nice but not necessary for an engine swap.

[Team WorldTour]

I know. I did my H6 conversion on Domo/ Dumbo in an unpowered barn with a dirt floor.
But a well lit shop and a lift are much nicer!
This will be finished in my sloped drive-way.
But this time, I had the Tow Driver help me put it on ramps, so I have that going for me now.
My neighbor has a crane I can use, I just need to find an engine stand and I can do it at home.
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

So, here is an update.
The motor builder is denying my refund, because he says I've mixed and matched the parts (Specifically, I've put a 1,9 in a van that came with a 1,6. Also, he say I don't know what I'm doing, despite in the last conversation, agreeing that I DO know what I'm doing.).
So, now I have to go find a lawyer...
FML!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

Still nothing from Tornau Motors, but my work (Pitstop) has gone and ordered me one from *their* supplier.
I have to wait a week or so, but I have one on the way!
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!

[Team WorldTour]

SO much has happened since then!
Pitstop fucked me over (again!), was unemployed (again!), and I'm STILL trying to get this f$^&ing motor installed!!!!
GGGHHHHAAAAHHHHHH!!!!!!

So, I have a different front plate on my motor. I can now enjoy the modern tensioner timing wheel! Downside is, the front cover didn't fit (surprise!), so I hit eBay and got another. I am now left with a hole, and questions.....

Is this where the motor mount would be located in another configuration?
The way the mototr sits, it invites dirt and rocks into the timing belt 'safe-space'.

Dear Samba: What To Do?
_________________
1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!