Author Topic: AAZ Crank Pully on Recently Manufactured Motors? (Read 3658 times)

dosma · « **on:** July 07, 2005, 01:17:48 pm »

I read in an earlier post on another list, that the latest aaz engines from Gernany have the updated crank/pully arrangement. The person doing my upgrade to 1.9 AAZ from 1.6 NA in an '82 Westy said the same thing. Can somebody with first hand knowledge confirm this or is this just a fantasy.

Is there a way to confirm the crank/pully/key arrangement without removing the crank pully?

QuickTD · « **Reply #1 on:** July 07, 2005, 08:12:22 pm »

I believe that new engines and reman engines are both coming with the newer type TDI pulley.

You can confirm this by reading the part number on the face of the crank pulley. You will need to remove the harmonic balancer/accessory drive pulleys (4 bolts) if they are in place, but you do not have to remove the crank pulley centre bolt nor disturb the timing.

The new TDI style pulley part number is 028 105 263D

The older troublesome pulley part number is 028 105 263E

dosma · « **Reply #2 on:** July 08, 2005, 12:32:10 am »

Once again, Thanks a bunch Quick TD.

When I have a few days to pull things together, I'll pull the harmonic balancer and take a look. I'll be under the vehicle anyway removing the turbo to replace a flange stud. It's a nice thought that I may not have to deal with the pully problem in the future, one of the good things about buying a product near the end of it's life cycle.

dosma · « **Reply #3 on:** July 08, 2005, 10:46:54 am »

Assuming that my crank/pully arrangement is the TDI version, could I follow the proceedure for torqing the 1Z TDI engine crank bolt as found in the '97 Passat TDI shop manual? I presently do not have a shop manual for a vehicle that used the 1.9 aaz engine. I also have a shop manual for the 82 Vanagon with 1.6 NA engine. I'm in the process of sorting out where I get info and parts for a late model 1.9 aaz engine in the U.S.

QuickTD · « **Reply #4 on:** July 08, 2005, 10:45:12 pm »

The crank pulley bolt torque is the same regardless of engine TD, TDI and even the gassers I think. Torque is 66ft/lbs +90º.

Pretty much all the bottom end parts are interchangeable from AAZ to AHU TDI, crank, bearings, seals, piston rings etc. Timing components like the tensioner and belt are also identical to the AHU TDI. Even the block itself is very much the same, some additional machining on the TDI for the crank sensor. Oil filter is also the same as is the oil pump, cooler, filter base etc. Most dealers now stock only the duraterm type glow plugs as "universal" replacements for both the slow and fast glow plugs of the earlier diesels, these will work fine in your 1.9TD. The only maintenance item that may be hard to find in the US is the valve cover gasket, it is different from both the 1.6 and the TDI. Not to worry, its rubber and can be reused many times.

dosma · « **Reply #5 on:** July 11, 2005, 02:45:25 pm »

I just checked and my Bentley manual for my '97 Passat TDI 1Z engine also covers the AAZ engine. Are the 1Z and AHU TDI engines similar?

QuickTD · « **Reply #6 on:** July 11, 2005, 09:47:19 pm »

I should have rephrased that, the 1Z and AHU are pretty much identical. Parts for either will also fit the AAZ. The 1Z may not have an EGR cooler and but thats about the only difference.

dosma · « **Reply #7 on:** July 12, 2005, 01:50:05 am »

It's all coming together. Nice to know that I already have a lot info on my AAZ from my TDI manuals, etc. Now that I have taken a good look at the two engines I can see that they are very similar in many respects. I'll copy this thread for reference.

I appreciate your help.

...Don