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AAZ- Once More, Into The Breach......
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Team WorldTour
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PostPosted: Tue Apr 13, 2021 12:36 pm    Post subject: AAZ- Once More, Into The Breach...... Reply with quote

Thank you, Uncle Sam, for the Stimulus Check!
It's given me what I need to start this again!

I'm not even going to bother with the old engine, I am getting a complete new one, and a new turbo (K14 (stock) this time! No more messing with ill fitting parts!)!

I've got a four-week wait for the motor to get here. I've just about got all of my seals and sauces and turbos and cornbread, so it's now a matter of organizing the transport to the shop!

After the old motor comes out, and the work is done, I plan on shipping the old motor back to the builder and just get it the F*CK out of my life!
NO autopsy!

Wish me luck!
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1990 Feldjäger Syncro AAZ
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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!
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DanHoug
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PostPosted: Tue Apr 13, 2021 12:49 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

like a NEW new motor or a rebuilt?

sometimes it just takes a reset to make everything right. it'll feel great.
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60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
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Team WorldTour
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PostPosted: Tue Apr 13, 2021 12:54 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

I may be inviting trouble, but I'm getting a 0km rebuild from the same company.
Shocked Rolling Eyes
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1990 Feldjäger Syncro AAZ
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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!
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Zeitgeist 13
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PostPosted: Tue Apr 13, 2021 4:01 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

GEX FTW!
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Team WorldTour
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PostPosted: Sat Apr 17, 2021 2:45 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

So, I posted this in another thread, but I would like to mount an EGT sensor and gauge, but need to find one.
Also, Gnarlodious, could you remind me of the larger exhaust set-up you did? I think I might try that out, too.
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1990 Feldjäger Syncro AAZ
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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!
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PostPosted: Sat Apr 17, 2021 7:23 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

I installed a 2½” exhaust, coudn’t be happier!
https://www.thesamba.com/vw/forum/viewtopic.php?t=728825
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Team WorldTour
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PostPosted: Wed May 12, 2021 5:37 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

So, here I am, at the workshop again.
Pulling the engine out, again.
Kinda disheartening to see gear oil coming out of the CV joint...
_________________
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!
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dobryan
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PostPosted: Wed May 12, 2021 5:42 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Team WorldTour wrote:
So, here I am, at the workshop again.
Pulling the engine out, again.
Kinda disheartening to see gear oil coming out of the CV joint...


Why do you need to pull the engine for gear oil in the CV? Isn't that usually due to the CV flange seal at the transmission?
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794
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MarkWard
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PostPosted: Wed May 12, 2021 7:15 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Gear oil out of the cv joint is likely the half dollar size cap has fallen out of position in the drive flange. I will smear a film of silicone around the outer edge once installed to help retain it. It can be knocked loose installing a cv shaft.
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dobryan
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PostPosted: Wed May 12, 2021 7:30 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

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

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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794
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Gnarlodious Premium Member
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PostPosted: Wed May 12, 2021 8:21 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

The output shaft is supposed to have a seal the prevents oil from coming out. I myself have had a chronic problem with oil leaking out the driver’s side output shaft into the CV boot. Even after replacing the seal it still leaks...
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dobryan
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PostPosted: Wed May 12, 2021 8:58 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Gnarlodious wrote:
The output shaft is supposed to have a seal the prevents oil from coming out. I myself have had a chronic problem with oil leaking out the driver’s side output shaft into the CV boot. Even after replacing the seal it still leaks...


Many times that seal does not work very well on its own. Did you add any RTV?
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794
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Team WorldTour
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PostPosted: Wed May 12, 2021 10:32 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Yup, that little seal was loose.

Motor is out for changing. After dinner I will update the thread with pictures 😃!
_________________
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!
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Team WorldTour
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PostPosted: Wed May 12, 2021 12:17 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Okey-Dokey Folks!
I'm happy to report, it was a good day of wrenching!

Wait, back up....

On Saturday, I got a trailer, and moved Frank to the workshop.

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


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


And from there I dropped the engine and trans together (to save time).




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


This is the Turbo. Nice and clean. 7,000 kilometers old.
(Oh, by the way, the van has been sitting in my driveway since I last wrote about him. 7ish months ago, or so. I haven't cleaned anything first.)


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


Air Plenum, oil soaked. I haven't opened it up yet. That's tomorrow!


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


Oil on the bell housing, but not the oil pan. I pulled the plug, but it was dry.


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


As promised, a CV leaking gear oil.


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


Yup, the little cap was loose. I tapped it back in with a socket and hammer. I'll give it a smear with RTV tomorrow.


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

Now here's a funny thing....
This is the bolt hole for the turbo bracket. The one I thought was sealed. (I used the wrong bolt the first time, broke it. It dripped. To my surprise, when the first motor was sent back for the roasted bearings, I got the same block back, with this repair.)

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


This is curious. My air ducting is (was\ should be) complete and assembled, so I'm not sure how this got flooded. Really, I wasn't planning on replacing the air filter. It's still new. It's soaked. Trip through the sandblaster, paint, find the next fault, Lather, Rinse, Repeat.

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


And here it is, four and a half hours later, out.

Tomorrow I will split the trans and motor and start pulling stuff off. I've got a bunch of new stuff, like the oil pump and Turbo, as well.

I'll take more pictures.
_________________
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!
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Team WorldTour
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PostPosted: Wed May 12, 2021 12:44 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Oh, and I also got some lighting upgrades.
I've got a question for the ones who have done the LED upgrade....

Where did you get a mounting ring for the lights?


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


It fits just fine, but a little loose.....


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


The H4 bulbs have the tabs mounted to itself. Can't get those off.....
_________________
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!
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?Waldo?
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PostPosted: Wed May 12, 2021 3:25 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

The US spec round headlights all came with the rings.
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MarkWard
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PostPosted: Wed May 12, 2021 3:31 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Team WorldTour wrote:
So, here I am, at the workshop again.
Pulling the engine out, again.
Kinda disheartening to see gear oil coming out of the CV joint...


It sounded like you already swapped the engine and then found the gear oil leaking. I’d reseal the trans while you have the engine out.
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old_man
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PostPosted: Wed May 12, 2021 4:38 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

[quote="Team WorldTour"

Where did you get a mounting ring for the lights?

[/quote]

I made some temp ones until I got the proper rings. Funny thing about temp fixes and how they end up permanent.

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Image may have been reduced in size. Click image to view fullscreen.
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Team WorldTour
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PostPosted: Wed May 12, 2021 10:57 pm    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Anyone feeling generous and charitable.....?
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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!
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Team WorldTour
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PostPosted: Thu May 13, 2021 8:43 am    Post subject: Re: AAZ- Once More, Into The Breach...... Reply with quote

Double post.
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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!


Last edited by Team WorldTour on Thu May 13, 2021 8:45 am; edited 1 time in total
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