Sunday, January 16, 2011

VW diesel

I have just finished tuning my Jetta.  Some months ago I purchased a 1.9L AAZ and transaxle from a wreaked '93 Golf.  It took me some time to gather together all the bits and pieces that I needed for the install.  Many parts on the AAZ were damaged and I had to source new or good used ones.  My biggest headache was the turbo. It was cracked.  It took along time to find a used KKK turbo that would bolt on without mods.  In the end I wound up using the 'Garret' from my 1.6L.  It was the easiest solution and I should have considered it right from the start.
Well, by Christmas time I had all I needed to do the swap.  So Dec 25th (Edie had to work), I pulled the 1.6 out of my Jetta.  Swapped the mounts and turbo, and over the following several days, wrestled the 1.9 AAZ and gearbox into place.  It was actually quite easy!  But, who would have guessed that the CV/axle flanges would be different diameters.  I discovered this only after  bolting down and connecting everything, yes, everything; the axle shafts were all that was left to do.  I should have just pulled the thing back out at that point.  But being the stubborn guy I am, I set about swapping the drive flanges while the gearbox was installed.  I can say that it was not all that easy to do.  It probably would have taken less time to re&re the engine/tranny (and a lot less hassel).  
I can say that I enjoyed the challenge and I would do something similar again.  I think, when  I finish my tea, I'll go for a drive :)


Time, gentlemen, please

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