Club 80-90 Forums

Firstly, I hope I aren't flogging a dead horse with my questions.

I need to swap my 1.6td JX with a 1.9 AAZ, and the free garage space I will be using will only permit me a limited period of time so I need to have my attack plan sorted. I have read Brick Yards guide http://www.brick-yard.co.uk/VehicleSpec ... ds/aaz.htm which is really informative, he will supply me a kit as well.

My questions are -

Does the engine drop from below or do I need to hire a crane?
Are there any other tricky things to watch out for that aren't highlighted in Brick Yards guide?
The turbo on the AAZ I bought is shot, has anyone used the JX turbo on a AAZ with success?

I hope to become a contributor on the forum when I have a bit more experience with the Syncro.

Cheers

engine drops down, engine crane can be handy to lift it back up with off the floor from the inside hatch.

Loadsa info on the Brickyard, not just the fitting guide. People do use the JX turbo and manifolds on the AAZ I believe

You have a p.m...

Cheers,

Andy

If you have an AAZ with a knackered turbo the rest of the engine will be similar, they normally last forever.

try looking at this link for some info given to me and by me as I did my AAZ conversion earlier this year.

https://club8090.co.uk/forum/viewtopic.p ... az&start=0

and here is a list of bits I bought:

Fit new JX parts: Number Price
clutch assembly 068 298 141 DX (110) £63.50
Crankshaft spigot bearing 111 105 313 A £5.50
Sump gasket 044 103 609 D (18.56) £7.01
Oil filler pipe gasket 068 115 315 A £1.22
Sump drain plug seal washer N013 849 2
Alternator / water pump belt
Water housing 'O' ring 2no. 052 121 091 A £1.00
Exhaust gasket (turbo to pipe) 893 253 115 £3.73
Exhaust manifold to head gaskets. 4no 028 129 589 B £2.25 each
Heat shields - 2 parts 068 253 283 & 068 253 283 A £13.76 each
Fit new AAZ parts (engine no - AAZ 504 742):
Timing belt & adjuster 028 109 119 P & 068 109 2430F £20.00 & £30.76
Oil cooler 'O' ring seal 028 117 070 £3.77
Oil Filter 068 115 561 B £6.59
Crankshaft oil seals (Fr 068 103 085 E) & (R 068 103 171 F) £4.17 & £8.45
Crankshaft oil seal gaskets Fr 026 103 161 B & R 026 103 181 B £1.46 each
Crankshaft pulley end bolt (M14 x 1.5 x 47) N905 771 01 £1.37
Flywheel bolts 6no N902 061 03 £1.84 each
Inlet manifold gasket 028 129 717 D £4.19
Inlet manifold elbow gasket 028 129 754 A £3.25
Water hose - pump to cylinder head (AAZ) 028 121 053 Q (19.85)
Coolant Thermostat 'O' ring seal 038 121 119 B £1.48
Timing belt cover 028 109 123 E £15.97

4.5 litre oil
Longer turbo oil return pipe to sump (JX +1")
Bung to back of block (end of AAZ oil return pipe?)

Prices in brackets are VW with aftermarket prices following.
Hope this helps
Garyd

Gee, this forum rocks, thanks to garyd, you have redefined the word "comprehensive", I cannot wait to to rebirth my bus with another pump.

You can get the engine in and out from the top with a crane. unbolt engine from mounts, support with crane, remove mounts and alternator and lift.
Just watch the arm of the crane on the rear door top lip. It's tight but it does go.

Ask HarryMann.

Also if your AAZ is the type with the sprung alternator tensioner, buy a new tensioner...mine failed and caused engine to cook three weeks after fitting it..
It looked good so we didn't change it.......

How do you identify that spring thing?

Your crane needs to be hefty because it's lifting the engine and gearbox in a one-er. I put a bit of ply across the rails of the crane and used it to wheel the unit in and out. You need the bus to be up on mega axle stands, though.

JX turbo and manifolds etc all fit, but you'd be as well getting a recond turbo while you're at it.

Don't forget the needle bearing where the gearbox drive enters the crankshaft socket.

Only problem I had was with oil level. Make sure your dipstick is set at the right height otherwise you'll over- or under-fill. Stick the full 4.5L in and then see where the level is on the stick.

Enjoy!

Might not even get on bottom of dipstick, so mod the sleeve..

Wiki on TD dipstick mod