AAZ into a 88 Weekender, conversion thread

91Transporter16" · Posted: Mon Oct 24, 2011 5:53 pm Post subject: Clutch Parts

Ben T Syncro, I am putting a AAZ in my Transporter that needs a flywheel, clutch and what ever else is needed to mount a 4 speed to this AAZ. The truck came with a 2.1L and I was told that the clutch is different. This truck originally came with a 1.6L and was converted. I am putting a AAZ back in it this time.
I'm also looking for the carrier bars that support the diesel engine for a syncro.
Thanks

Tony

dubbified · Posted: Sun Oct 02, 2011 10:09 am Post subject:

Zeitgeist 13 · Posted: Sun Oct 02, 2011 9:26 am Post subject:

Does anyone have pics of the kickdown cable arrangement for diesel swap with an automagic tranny? I'm still debating my transmission options for an upcoming mTDI swap, and really like the idea of a slushbox churning away in front of that bioburner. I'm getting lazy in my old age, and look forward to letting the pump and valve body handle all the shifting duties.
_________________
Casey--

'89 Bluestar ALH
'01 Weekender --> full camper
NEAT, no ICE.

BenT Syncro · Posted: Sat Jan 29, 2011 12:51 pm Post subject:

brent239 · Posted: Sat Jan 29, 2011 11:50 am Post subject:

this auto has 225/70/16!! theyre huge and fit well. but yeah I hope its fixed too!
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88 westy suby 2.5

BenT Syncro · Posted: Sat Jan 29, 2011 11:48 am Post subject:

No biggie on my Syncro which was a turbodiesel from the factory. Good point that the Syncro trans mount idea would not work on an auto.

I'm interested in the ratios 'BlackDog' used for his AAZ with an auto. I've fitted a great number of shorter sidewall tires in my auto Vanagons but never a taller one.

Congrats on possibly saving that AAZ. We acquired an abandoned conversion before because the DPO thought the water was shot. They couldn't get rid of all the white smoke. Turned out to be a lot of water in the exhaust system. It eventually dried up and was no longer a problem. Maybe your engine problems are history now too.

brent239 · Posted: Sat Jan 29, 2011 11:12 am Post subject:

yeah the biggest deal was to an automatic gearing, which is way higher. In your syncro, you shouldnt have any problems gearing wise. and im not sure of any syncro diesels mounts, but as in all other syncros, im sure you could drop the motor and clear the lid, thats what my father did over 10 years ago in his diesel westy. I know theres more than a few syncro turbodiesels around.

FYI if youve been following this thread, motor sat over a week, ran some seafoam straight into the injection pump at like 50/50. ran pretty good yesterday, no runaway, idles well, just may have been a ring unseated??
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88 westy suby 2.5

BenT Syncro · Posted: Sat Jan 29, 2011 11:06 am Post subject:

BlackDogVan · Posted: Sat Jan 29, 2011 10:53 am Post subject:

FYI I ran a AAZ for 7 years on stock 2.1 wbx gearing & oversized tires. No problems & happy engine.
_________________
Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka...

BenT Syncro · Posted: Sat Jan 29, 2011 4:54 am Post subject:

I'm contemplating a similar swapped and hoped to hear how things turn out with the existing ratios. Will you be able to report back after the owner sorts out the problems? BTW, you could get some deck clearance by using Syncro mounts.

Anyway, I originally thought of using a TDI but that was shot down due to the ratios. I have an AAZ in my Syncro 16 but it's a Doka and originally equipped with a JX so no biggie doing the swap there.

I'm posting in the hope that you update the thread with a success story.

Cheers,

BenT

brent239 · Posted: Tue Jan 25, 2011 2:17 pm Post subject:

Sadly its not, its out of my hands/hair soon. owner decided he want to run it without me, ranaway now it only starts with half a can of starter fluid, pretty sure theres a cylinder with no compression or something. owner believes it to be the injectors, i think the wasted turbo spitting oil into the cylinders, led to the runaway, that wasted something in the motor. wont let me take the turbo off, do a compression check, or anything, well with my hands tied Crying or Very sad

, I will worry about my own van, and my tranny problems Crying or Very sad

hopefully soon fixed so I can move on
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88 westy suby 2.5

evansdd3 · Posted: Mon Jan 24, 2011 3:20 pm Post subject:

Hope the van's back running again soon.
You have to want to tinker to own one of these...I am reminded of that almost everyday!
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C'mon, gimme your 71 type 2...And throw in a dash clock.

evansdd3 · Posted: Mon Jan 24, 2011 3:20 pm Post subject:

Hope the van's back running again soon.
You have to want to tinker to own one of these...I am reminded of that almost everyday!
_________________
C'mon, gimme your 71 type 2...And throw in a dash clock.

BlackDogVan · Posted: Tue Jan 18, 2011 7:55 pm Post subject:

Everything you need to know is here. Better chill a few or put the kettle on...

http://www.vwdiesel.net/forum/index.php
_________________
Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka...

brent239 · Posted: Tue Jan 18, 2011 5:51 pm Post subject:

the oil is definitely coming out of the turbo. I dont know the history of the motor other than what the Junkyard told him. I wanna check the turbo for play. It doesnt look hard to remove, any consequences? any parts I should have? thanks for the help guys
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88 westy suby 2.5

BlackDogVan · Posted: Tue Jan 18, 2011 2:46 pm Post subject:

Check the turbo shaft too, excessive play side to side & any axial play can be an indication of shot shaft seals. Your turbo vomiting oil into the intake can cause a runaway.
_________________
Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka...

danfromsyr · Posted: Tue Jan 18, 2011 2:31 pm Post subject:

Ohh what a run away train wreck, it could end up being.
I speak from my own experiances. of course.

GET YOUR DIPSTICK IN PLACE AND WORKING.. I understand the challanges, I've a few issues when I oput the TD into my 1980 camper a few ye4ars back, and in mom's 2.5l eurovan swap I had to drill the block and install a tube.

the Engine crankcase NEEDS to vent, it DOES NOT need to vent into it's intake. seperate the 2 from each other till you have crankcase pressure sorted out.
catch the breather vapors into a 'catch can' for the time being and if you have excessive oil then fix that issue. it should breath, but collect very little measurable oil.

2ndly and this again from experiances in self destruction.
you NEED TO HOOK the AT trans kick down into the throttle cable.
it is a 'varied' input that effects the firmness of the shifting based against the AT governor, if you leave it disconnected you risk damage to your friction discs (too soft a shift) or it won't up shift till 45+mph and that's just plain unfun in traffic.
on my brother's AT conversion (Audi 5cyl turbo fwiw) he ran a 2nd cable to the front (bulk bicycle sheathing) pedal 'bellcrank' attachement.
this AT cable enacts the kickdown as well, so the Engine throttle has to stop(bottom) before the AT cable, which will have a click into 'kickdown'
on Mom's AT conversion (eurovan 2.5L fwiw) I made a cable using a MK-I/II golf/jetta/cabriolet AT throttle cable which includes a sprung slipjoint section to allow movement after the T-body is WOT. on
on this install I used the stock vanagon AT throttle cable from pedal to AT lever, then made as necessary the modified (t-body was too distant) MK-I/II cable relay.

lastly
Kudos and keep on pushing forward.

Dan in NY
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MarkWard · Posted: Tue Jan 18, 2011 2:20 pm Post subject:

Do you know the history of the engine? If it was overfilled, oil could have gotten up into the breather. It is also possible the engine has too much blowby and compression is forcing the oil into the breather system. Mine will spurt a slight mist with the engine running, but not enough to run on to the ground and leave a puddle. Perhaps running the engine will seat the rings back in and the blowby will be reduced. You can run the valve cover hose into a catch can for now. The catch can needs to vent. Cap off the other end for now. I can't tell you why it won't start now. A runaway diesel is a scary event. You will need to go back and check the basics. Verify the glow plug amp draw, crack the injector lines to be sure the pump is still primed. Not knowing how bad it ran away, it is possible the valves may have hit the pistons. A compression test will determine if that happened. How does it sound when you crank it. Also it sounds like you have some electrical shortcuts. Be sure the pump cutoff solenoid is getting power with the key on and during cranking.

edit: a clear supply hose between the pump and filter is helpful for diagnosing engine running problems.

brent239 · Posted: Tue Jan 18, 2011 2:04 pm Post subject:

well the runaway was gone, now its back. on the top of the valve cover that piece is leaking oil back into the turbo intake feeding oil into the motor causing it to runaway. I'm unsure of oil level. I think it may have to much oil. we've drained the oil previously and replaced with only 4 quarts, well were trying it again. I removed the tube on top of the valve cover now it doesnt it start. but Oil dripping out as it cranks over.

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

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88 westy suby 2.5

DAIZEE · Posted: Mon Jan 17, 2011 11:43 pm Post subject:

why is the air filter there and not up the left rear shaft? That rig looks better than mine (I mean the air filter hose & filter). What is it? I have a K & N?
_________________
'09 2.5L Jetta 5 cylinder, 5 spd, super turbo, see thread in H2O Cooled Jetta, etc...
83.5 Vanagon L Riviera Model with 98 1.9L TD AAZ 4 speed Daily Driver 3 out of 4 seasons (sold)
84 Vanagon GL Wolfsburg Westy WBX 4 speed (sold)


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AAZ into a 88 Weekender, conversion thread
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