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Yet another JX to AAZ swap log

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mastakilla View Drop Down
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    Posted: 08 Dec 16 at 13:48
Hello, I have bought a '88 multivan with a blown JX, runs well but coolant is full of oil, still not sure if it's only the head gasket or if the head is cracked...anyway, I've done the sensible thing and bought a 1.9 TD: the seller states that it comes from a GTD Golf, but looking at it, it seems that the pump is the flat top "eco" one. 

Someone can confirm? If so, which are my options to give it a bit more poke, I have the old jx pump which seems OK, which is better?

My plans are to strip it down to the bare block, fit new rings and bore it if needed, rebuild it with new everything and fit it to the existing 5speed box. My mod list 
- fit a new crank pulley with new bolt, if I find the crank nose ruined I might fit a retainer pin
- use the clutched alternator pulley
- oil rad
- slight pump mods if allowed








Edited by mastakilla - 14 Mar 17 at 11:37
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ob1 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ob1 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Dec 16 at 14:50
''Tis an AAZ. Slightly rubbisher later pump but it'll go ok.
Don't use the JX pump or injectors just look and fit an earlier pump with a decent boost pin and good to go.
If it's a known good engine I'd personally just slam it in. There are pretty indistructable with regular oil changes so long as they don't get too hot. Crank bolt pulley is a must. Change every cam belt swap as well. Use the JX v belt set up for less strain on the system or as you're saying use a clutched pulley.
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mastakilla View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 08 Dec 16 at 16:24
Thanks ob1 for the info! I'll start looking for a pump then, from a quick skim thru the classifieds they seem to go for as much as I paid for the engine, but I'll keep looking.
The fact is that I know nothing about this engine, it's being delivered to me on a transpallet, removed from a van of which I know absolutely nothing, so I thought of giving it a proper refresh for peace of mind essentially
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ob1 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Dec 16 at 17:03
It'll be ok with that pump. Just a bit flat.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote oxford_rebel Quote  Post ReplyReply Direct Link To This Post Posted: 11 Dec 16 at 13:14
I had that pump on mine and it was ok, better than the previous JX. It died and I fitted a later LDA pump a year ago, that was much better, then a Brickwerks boost pin and it went really well, even my usual (experienced with AAZ T3) mechanic said it was the best AAZ he's driven. It's now got a cracked block so an AGG is going in and my pump (and nearly new injectors) will be for sale shortly.
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mastakilla View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 12 Dec 16 at 13:12
Hi! If the cracked block is not a consequence of the pump, let me know when you have it for sale :)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 17 at 11:28
Hello again, I'm finally installing the engine, and while preparing it some issues/choices to make popped out

- the engine came with some badly modified support arms, to make space for the exhaust manifold and turbo, so since the old JX manifold/turbo seem to be in good shape, we are thinking of mounting them in place of the AAZ stuff, this would allow us to use the original untouched support arms. Is it a good idea or should we go with the original AAZ parts?

- as much as i'd like to source a proper LDA pump, they are all expensive and at this point I just want it on the road, I'd leave its eco pump but if there's something to be gained from the JX pump, I may use it... old question I know, but still

- we found this "piece" to be a little worn, but I can't find a replacement...it sits below the alternator, and has a shaft in it that rotates in a bushing (which is the worn part). What's that and where do I find service parts?



Thanks guys
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ob1 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ob1 Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 17 at 19:40
Use the Jz manifold and turbo. You need to adapt the oil lines a little. Or buy new ones from brickwerks.

Use the AAZ pump and injectors. It'll be fine - or I've got a decent know good AAZ pump sitting here?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 13 Mar 17 at 15:55
Just spent an awful lot of money for bits and bobs..in the end went all out and even splashed for a full silicone pipes kit.
The only parts that I haven't been able to source online are 

bushings  028903313
grommets 028903310

both related to what I later discovered is the serpentine tensioner assembly pictured above.
Will have to scour the junkyards to find a good casting as mine is worn in the alloy.
What now concerns me is the fact that there's some leakage around the crankshaft seal, I'll fit new seals of course but I hope it's not a symptom of the dreaded AAZ self destruction...couldn't check the crank pulley as the engine is separated from the gearbox and the mechanic told me that he needs it attached not to lose the phase.
Fingers crossed...


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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 10 Apr 17 at 08:13
Engine is almost ready, waiting for the alt. bracket to come from somewhere so we can close it and put it back in the van.
One curious thing is this: I bought the extended oil return line from brickwerks, thinking that it would've been needed to fit the JX K14 turbo to the AAZ block, but in the end we reused the old one as it fits perfectly, while the extended one is too long and can't even befitted properly without doing ugly bends.
Are we missing something obvious here?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 17 at 09:05
Hi, engine is in, almost done connecting all the bits, at least it seems to run fine.
There are now some small minor issues, maybe you can shed some light on them (if anyone is reading)

- I've used the JX manifold and turbo, but the turbo sits a bit higher than in the JX. as a result, the JX downpipe now sits a bit higher too, and does not line up well with the exhaust back box.
I don't see this problem mentioned much elsewhere, how do people solve this? I can modify the downpipe with a flex section, buy the spacer from brickwerks or just force it in place

- The AAZ alternator seems a bit worn, so has to be rebuilt. I've realized that maybe by using the AAZ alt the original revcounter may read higher. What's best to fix it? Is there some pot in the cluster? I may use an Arduino to build the correct signal out of the AAZ output, but I'd avoid it if possible

Thanks!
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ob1 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ob1 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 17 at 16:01
I recently used the brick-yard spacer which worked very well. Although I've found you can usually bodge it all in to place with a drill and enthusiasm.

Did work better with the spacer plate though!

Not sure about the alternator.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 17 at 21:35
I've sourced a 120A alternator from a TDI, which comes fitted with the clutched pulley, I have modified it soldering a wire on the back to get the W output and drive the tacho.
Now I have a couple of issues

- The engine seems to sit a bit too close to the rear of the van, in particular the crank pulley is very (like 2 mm at best) close to the exhaust box. I've checked the mounts and everything, there doesn't seem to be any obvious way to move it a bit forward. Is it normal?

- I've fitted the brickwerks throttle arm lever, which is cool. In doing so, I have lost the original position of the small screw on which it screws on: I have refitted it so that at rest the screw sits at its "closed" position, but I don't know if it's the correct way of setting it. Is there a guide somewhere?
Also, the throttle cable is too short and can't reach the lever, I had to extend 2 cm it with a bodge, surely that must be wrong.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 14 Sep 17 at 07:49
what gearbox code have you got? 
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ob1 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ob1 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Sep 17 at 10:43
Mine was the same as this. Cable to short with brick-yard throttle lever as well.

I bodged it with a bit of flat steel.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mastakilla Quote  Post ReplyReply Direct Link To This Post Posted: 15 Sep 17 at 08:29
@mrhutch not sure about the code, can't check it now but it's a 5 speed unit. It's the one that was originally attached to the JX

@ob1 ok so that's normal, don't like it that much tbh, I also had to enlarge the hole with a file or the screw wouldn't fit. I'm thinking of using a stiff spring instead of a piece of steel to connect the lever to the cable. In my mind it would work kinda like the original double spring mechanism, reducing cable stretch.
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