Giving our VW T3 (Vanagon) a new engine! Step by step 1.9TD AAZ conversion (part 1)
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- Опубліковано 7 лис 2020
- After the van decided to die on us when going home from our grand Norwegian road trip, we had to get busy changing out the engine. Luckily, we quickly found a 1.9TDK AAZ engine that we started fixing up. Let’s show you the process of swapping out the standard 1.6TD with this 1.9 AAZ, doing it step by step and also showing the parts we needed to buy in order to make the engine into a "new", reliable piece of machinery. Stay tuned for part 2 where the engine gets installed :-)
/ benedikteroness
/ simonbraeck
/ huskyzulu
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#vanagon
#engineswap
#4K
#AAZ
/Simon
Totally out of the comfort zone here, but we’re learning and hopefully it can be helpful for others too. Do you think we’ll be happy with this "new" engine?😄
looks like you will be very happy! You picked a great engine, and now with all the cleanup and refurbishing you're doing, it will be like a brand new engine. Congrats!!
Absolutely 💯 % 🤞👍👌👏🤩
I think you will be. Subaru is the common choice here in the US, but I've seen plenty of people swap out for an AAZ as well and they seem to be much better than the Wasserboxer and original diesel engines in every way. Better power, better fuel economy, OBD-II fault-checking... I think you're going to be very happy. It's such a good feeling to go from worrying every time you go on a long trip to trusting that you're going to get where you need to go. Plus, IDK what it's like in Norway/Europe in general, but in the US, it's very hard to find mechanics who will work on Wasserboxers or VW diesels from that era. A modern motor dramatically opens up who can work on it if you break down in the middle of nowhere. Great first video!
Remember , better performance means you may travel faster. Travel faster requires better braking. You both seem very sensible so look further ahead. Great video.
I think these vanagons (T3) make us do that....same here, learning first on installing a used engine (gas) and then doing a subaru conversion...definitely learning....
I really love watching the two of you. I love seeing the joy and excitement in your eyes when you find another hidden surprise.
Thanks mate, we hit the jackpot with this one. Can’t wait to test it out! 🤗
Wow!!!!! Thank you for sharing this. Very interesting to see the whole process. I can't wait for the engine to fire up with a turbo. Damn...it will be a hot wheelie!
Sure thing😉 I’m so excited to try it out, we’re still waiting for the new diesel pump to arrive.
@@SimonBraeck Any news on the transmission if it needs a rebuild?
We took out our 1.6TD JX unit and fitted an AHU from a Sharan. It came with power steering and cruise control - luxury!
So glad you guys are back on the road. That engine looks amazing. Many happy miles ahead for you guys. Watch the tide this time lol
We learned the hard way last time, I doubt it will happen again😅 Can’t wait to try this engine out😊
Excited for you guys knowing SO MUCH about how your van runs after this!
Thanks! Exactly, really steep learning curve but we’re getting there😄
Nice to see that you are making big progress with the spare engine.👍 Looking forward to the moment when The new heart starts beating.
Keep us updated.
Thanks! Same here, can’t wait😃
My new favorite video) Good luck guys, really enjoy your approach!
Thank you, so much fun doing this engine swap!
Keep on going guys, really respect you for never giving up and always finding a solution. Good things come to those who wait ;-)
Thank you, quitting is not in our nature😊
We once had a 2l Diesel T4. Not very fast but so fun to drive. And the sound was amazing ♥
So glad to see that you and the van are back on the road! Can't wait to spring when we will do the exact same thing! :-)
We’re getting there😊 Oh, exciting times ahead👍🏼👍🏼
Wow! That engine looks so clean! Fantastic work.
Thanks! Hopefully it will last us a long time😊
This is very exciting! Luckily the new engine is in great shape. Good job taking it apart for a deep clean and some parts swap. That tool that cleans thw parts is very handy. Never seen it before :)
Yes, we’re so close now. I can’t believe we were so lucky with the block. That tool is magic, turns old stuff into brand new ones, great for the environment too I guess😄
It's good to see that your van's engine is getting better...💪Hope you hit the road as soon as you can.❤.Cheers..God bless you 🙏
Thanks! I really look forward to it being finished😊🙏🏼 take care!
Glad to hear things are getting better with the van. Hard will will pay off. Cant wait to see some more travels and awesome cinematic videos.
Thanks Eric, it’s getting there eventually. Hoping we can take it out for some winter/snow fun the coming months!
Just WOW! I have the same type of engine in my T3 and i think its the best fit if you dont want to do a transmission upgrade too. But i really cant believe you could easily find one in such good condition! I just read everywhere that theyre long gone. Again wow. Wish you guys plenty of km without an issue. Looking forward for part 2.
I know, totally lucky without knowing anything when buying it. Can’t wait to test it out once everything is in place😊
Congratulations with a new engine, I hope it will serve you well! Fun to see the mechanics and the work they do.
Thanks, hopefully it will run like clockwork once it’s installed😊
@@SimonBraeck Let's hope so. Lykke til!
Great video Simon. Really enjoyed seeing everything step by step. Looks like you found a great little motor. Greetings from Mexico.
Thank you 🙏🏼 We got lucky with this “barn find”. Can’t wait for the first test drive😊
Very good, I have owned a t4 for 20 years with 198,000 miles on theclock it is still going well!
Solid machine!
Good luck with the new engine!
Great videos. I hope you are back on the road soon!!
Greetings from austria! 😉
Thank you! Shortly ready, can’t wait to try it out😊😊
And a flywheel, looking good guys . Thanks for sharing.
I think it’s gonna be good! Thanks :)
Man, the crankshaft had to be replaced with one from 1z / ahu, it fit 1 to 1, but it would have lasted a lifetime, and it would have required a pulley with a clutch on the alternator, greetings from an AAZ enthusiast in Romania.
Amazing!!! You are doing an incredible work. Congratulations.
Thanks Hugo! We try our best👍🏼
That’s going to be a smooth ride, ready for winter adventures 👌🏼
Hopefully that’s all correct😊👍🏼 can’t wait
@@SimonBraeck fingers crossed for you 🤞🏼
Great video! Can't wait for the next one!!
Thanks! Me neither, haha😊
always a pleasure to see your videos 👍
Thank you🤗
Excited for part 2
Me too😇
Very nice! We had a non turbo 1.9D 1Y in our T3. We also got it completely rebuild and was running like a dream! You should know that the 1.9 engines have a longer stroke than the 1.6 engines. So they cannot make the same high RPM's as the 1.6 engines. This means that your topspeed wil be lower.. if you drive the same topspeed with the 1.9 you will wear out the new engine really quick. For us this meant we had to get a new gearbox with longer ratios. Since our T3 previously had a 1.7. You had a 1.6TD JX, so I guess you will already have a 'long' gearbox and you will be fine ;)
Thanks for the advice! I’ve been told that the JX gearbox is capable to handle the 1.9 without much problem, but we’ll have to feel it out once everything is in place. Can’t wait for the test drive😊
@@SimonBraeck If the top gear proves to be too low, bigger tyres are the first thing to try :)
Can't wait for part 2!
Me too! It’s been too long... :(
Excellent work and brilliant video! Look forward to next video as our 1.6td California needs an aaz too!
Thank you! Can’t wait to try it and give my opinion about it
well done Simon, I love watching your videos and learn quite a lot from them. My T3 has a 1.6 CS diesel and it is very slow but I don't have the courage nor friends to help me put in another engine. take care and I hope you and your wife (and dog) can soon start travelling again with a more reliable and powerful T3. Good luck !
Thank you! I can totally relate to this, didn't know much before we met these guys. Reach out to the T3 community if there are any close to you, you'll be amazed of how helpful and passionate this group of people are! Friends for life :) Thanks, I wish the same for you
@@SimonBraeck hava soğutmalı 2000 CC t3 ün motorunu değiştirmek.
@@SimonBraeck t3 hangi su soğutmalı motor uygun
Good progress made guys 👌🏻
Thanks, we’re pleased so far😃
Amazing work 😍
Thanks! :)
Great video very sensible to replace as much as you can during the build, shame the old JX died we had the same in our T3 and it never put a foot wrong in the 8 years and 50km we put on it, it had a total of 179000km when we sold it.Can’t beat a T4 had ours for nearly 9 years.
It’s a shame, but I hope this will be a reliable upgrade that will power us for many more adventures the coming years. That’s true, our friend which always keep saving us have a syncro T4😊
Always funny to watch your adventures! 👌👌
Thank you☺️ Hoping for many more once the engine is ready!
So glad you didn't go the Subaru route. You've got a bullet proof engine if maintained like all engines should be. Real stroke of luck that you unknowingly got a low mileage block. Looking forward to the next video👍
Now we finally know how an engine works😄 And super lucky to find this «gem» of an engine, hoping it will willingly power us forward for years to come.
good luck !
Thanks :)
Looks fantastic brilliant can do attitude.Congrats...
Thanks Alex, we love taking on challenges like this and we learn so much as we go!
For the age, you guys scored on that engine. Barely any discoloration on the crankshaft, clean skirts on the pistons. Again, great find. Must've been some kind of old owner car or maybe a fleet car considering how clean it was.
Indeed, we hit the jackpot with this one. Can’t wait to try it out properly!
I just purchased an AAZ for my T3 in California. Let’s see if the restrictive government of California will let me register it. Wish me luck! 😎😎😎👍👍👍
Oh wow, exciting! Let's hope they are cool with you swapping for that AAZ! Good luck😊
@@SimonBraeck thank you. I enjoy your videos. Have fun!
AAZ still powering up my Golf MK3. I have impression that this thing will outlive the rest of the car. I was surprised that valve cover was still having some paint. Mine do not have it already :D It`s 30 yo.
Awsome guys!
Thanks, so fun doing this project together!
if i may suggest, key to keeping any engine running for a long time is 3k mi/5k km oil changes. even with synthetic oil. Good Luck!
Like it, great job. Gratulations 💞👍
Thank you!
I’m really glad your channel popped up in my feed! Video editing is great. You should have more subs very soon. Is the van your daily driver?
Good to see the strong, pretty woman turning a wrench too!
Thank you James! We only have one vehicle which is this van, but it’s not needed on a daily basis. We live in the middle of a city so it’s not the most convenient vehicle in rush hours etc. I know, she is pretty handy!
It's great to see how much you guys are doing yourself, a lot of people would have just got someone else to do it. You'll appreciate it a lot more knowing what's gone into it and if something was to go wrong when your out on the road you've got a better understanding of it and be more likely to diagnose and fix it yourself. Much respect!! Was this filmed a while ago or is this quite recent?
Indeed, we wanted to be involved in the process as we have experienced mechanical skills are valuable as T3 owners :) We started mid September and we now wait for the diesel pump and finding a place to install the engine into the engine bay.
great video!!!
Thanks :)
I wish you a lot of success with the new engine and that you will be able to discover a lot of new things when you travel the world with the Bulli.
Thank you, that’s why we put in the work. Hoping for many more trips with this new engine!
@@SimonBraeck you both are really great role models as well as Daniel...Natascha ... I am so happy to make a first long trip to Norway in 2021, when the topic of corona is settled. These places I have seen at your place are just unbelievable for a T3 owner ... THANKS YOU stay healthy !!
Thanks again, I’ll let the know too😄 Oh cool, I hope you get the chance to go, I think you’ll like it 🇳🇴
Good luck there
Thank you!
Great to see Van Norris being repaired and how it is progressing, can’t wait to see it in action. Will you be having winter adventures ?
Thank you :) I really want to, let’s see what happens!
amazing video! after such a deep reconstruction of the aaz, i would think you'ld repaint the valve cover... hehehe cheers and im looking forward for ep.2!
Thank you! It’s on the to-do-list😄
Powder coat it, two tone, with crinkle finish ??
The 2.5 is the real workhorse, but if you take care of the 1.9, it will hold up for a long time 👌
I sure hope so😊
Hello Simon! How familiar is your feeling of delight and at the same time anxiety and slight tremor) I congratulate you on such a wonderful engine and such wonderful specialists who help you in all your courageous actions. I had to fight my AHU completely alone. I came up with everything myself ... And work with the wiring ... the fact is that I got a trade Passat 5, from which it was possible to remove everything ... naturally, I did not want to take extra wires for myself, so the process of collecting the wiring was very difficult for me ... (it was further complicated by the fact that the car was not in the garage all this time and had to break away from the engine on tour I congratulate you from the bottom of my heart) your motor is millions of kilometers! good luck!
Hi😀 Oh my gosh, that sounded very tough, the wiring is really something I don’t understand much of and one of the main reasons we didn’t look for a TDI. I hope the end result was well worth it for you and let’s hope our vans will last us for many many years😄
@@SimonBraeck They will undoubtedly delight!)) I transferred (through my stupidity) a sore from the old motor to ahu ... the oil pump bypass valve does not work ... in cold weather (as now) it tears off the oil filter !!!! I looked at your video with envy))) how did you clean each channel in the engine)) I was too lazy to do it properly ... now I pay off ..
@@SimonBraeck By the way, you are very lucky that the geometry of the turbine allows you to install the engine without "bullying" your mind))) in principle, you are lucky in everything!))) I am very happy for you, for you fourth!)) I am waiting for your exciting adventures! from St. Petersburg with love)
Sorry to hear about that issue you’re having, we learn as long as we live. I’m really hoping we did everything properly so that we can rely on the engine for quite some time😊
Amazing 🤩!
Thanks!🙏🏼
Nice !!! Keep up the good work !
We just doing same thing her, but with an 1Y engin. :c ^^
Thanks! Cool, sounds like a fun project😉
Part 2 please 👌🏻🤙🏻
Waiting for the diesel pump, super delayed and stalling the process... :/
I would have put that engine back again. looks good to go for another 30.000km :D
excelente video !! saludos !
Gracias😊😊
Nice project... you seem to have some really great people involved. I might be able to help you out.. I have been running an AAZ Vanagon for 15 years and have rebuilt my own engines and transmission... including mods of all kinds... the best mod I made was in gearing to significantly lower highway engine RPM. I am sure there are many people out there more knowledgeable but if you need advice feel free to reach out.
Talk about "barn find" engine! Looked barely run in! That partswasher must be lifesaver - the results look incredible. I hope the rest of is turns out great - and that there's a dyno in the engines future! I, for one, really wonder what performance you can get out of it. Safely, of course. Detonation not wanted 😁
Oh yes, such luck! Indeed, it’s really a magic machine which enables us to easily refurbish parts. Can’t wait to drive it and tweak turbo/diesel pump😊
@@SimonBraeck Having cooling with the blasting agent means you can to thinner gauges wihtout warping too, I guess. Roaling Coal, Veedub style, are we?😂
Now it is time for my van time change engine :D
nice!
@@SimonBraeck hey i am interested what fuel pump did install ? Is it your,s originall or did you combinated from somone elese ?
We installed a refurbished JX diesel pump :)
I instaling new engine :)
Can you say your post adres whear to send some small present for you ;) i see that you traveling with one mising part ;)
Altså Simon nu e du legit mer mekaniker enn æ har non gang vært 😜
Haha, æ jatte mest bare med! Men man lære alltid nåkka, flinke folk vi har på lag her.
what a great job ! if you don't like it when it's finihed, you can always give it to me for my t3 ! :)
Haha! I think we’ll like it though😂
You're driving a Vanagon. You have to be up for challenge!
Great video with a lot of useful info.
Would you, please, tell us the gain in both power and couple of the new AAZ (vs 1.6JX) ?
Lykke til!
Takker😊👍🏼
You young man are very lucky to have a willing skilled mechanic & = fine lady partner.
I totally agree☺️☺️
Amazing luck and good work! But... don't you think this carefully refurbished heart deserves some kind of transparent cover with LED lights when mounted back into the Norris? Keeping it hidden from daily view is just outrageous 😛
Thanks! Haha, that sounds fun. Would be easier to inspect too😄
Good work^_^
Thank you!
Congratulations. Now then, would you be interested in a camper exchange? Time frame late summer 2021 for about 3 weeks. I have a 2018 Lance 825 truck camper on a 2017 Ford F-250. I'm based in California but travel the country and could rendezvous anywhere. I owned a 1982 Vanagon, lived in Germany for 14 years and traveled all over Europe with it, as far as Kirkenes. I'm anxious to take a nostalgic trip from Oslo up the Norwegian coast.
Saludos desde México.
Simón Ya le instalaste el nuevo motor?
Hola! My spanish is not top notch😬 We have not installed the engine yet, waiting for some parts and a proper garage where we can do this.
Great video as always !
I would like to know how much does it cost to clean and rebuild an engine ? Approximately ...
Thank you and i can't wait to hear the song of this new engine :)
Thanks! It depends on how much work you do yourself of course. The engine and the parts right now is well passed $3500
super félicitations
Great progress. A turbo! Where do the new wings go?
Thanks! On the pop-up roof😎
Wow, amazing!!! But... where did you get that Volkswagen Jacket from?😄
Thanks! It’s my friend Rikard’s jacket, he got it from his days at a VW garage:)
Such a cool and interesting video! Do you think the new engine will also make a difference in fuel consumption?
Thanks! I’m not sure, I thought the old engine was pretty good regarding that actually. But my friends say we can expect roughly the same, but more torque at low rpm’s
Nice job ;) like like like ;)
Thanks😊😊
@@SimonBraeck Go go go .. you are welcome :) whaiting for more action..
It's really nice to see that you left no stone unturned when replacing the engine. You clearly had the work done by experts, and it's piece of mind for future travels that there is a good chance you will make it there. We know what it feels like to break down, but decided to go the expensive route and have a full rebuild as we use the van so much. www.daswolfgang.com/a-new-heart-for-wolfgang/
Hi Andrew! You’re right, we wanted something reliable when we decided to swap engine altogether. Hoping it performs like we want it to. Great thread you linked there and what a beautiful van you have. Are you liking the AAZ? :D
Hjemmelagd er vellagd heter det, og å ta kontroll på alle aspekter av bilen er en trygghet når man er langt hjemmefra. Det hjelper lite med bobil til en halv million om man må ringe Falken og sove på hotell halvveis til Italia når varsellamper lyser. Dette kommer dere til å ha igjen for senere.
Det kjennes godt ut å vite status på alle deler og være sikker på at ting holder. Også er det som du sier god erfaring å ta med seg😊👍🏼
Im really curious for the performance, as im having a 1.6 td as well now!
I’ll be sure to report back once the engine is running😊👍🏼
Vi har også den typen motor i vår bil og det er en stor forskjell. Håper dere kjøpte nye bolter der hvor det er spesifisert at det må byttes bolter.
Kult! Gleder meg enormt til å teste bilen når motoren er på plass. Jepp, har gjort det etter boka😊👍🏼
hey team and nice video almost step by step. But as far as you might know is there any petrol engine modification possible with turbine, and recommend please based on your climbing experience with mountains -> whether petrol engine is suitable and what power at least I should count on for rides also with comfort mountains climbing(roads + some off-roads available for most regular cars). THx and if any recommendations -> would love then to get in touch team !
Good video, I don't understand why you did a full rebuild on what was an un worn engine?
I have just fitted an AGR engine to my T3 and did nothing but service it when fitted. Anyway hopefully it will go as well as mine when fitted and running
Thanks. We did a complete overhaul to be sure things will work as expected since we dismantled the entire engine. The previous owner didn't have the history of the engine, so we wouldn't risk anything.
@@SimonBraeck These 1.9 TDI engines
These 1.9 TDI engines are tough as nails I was a service parts manager for VW at the time and they made our lives easy. The engine I fitted had done 133k and o would expect it to top 300k without problems with regular servicing, the increase in torque is a joy, I kept all the electronics on mine and fitted the OBD port for easy diagnostics. Hope yours goes as well as mine does
A TDI would be the ideal choice, but I think this is a worthy upgrade from the standard 1.6 right now. In the future we might change our mind and choose a TDI, but then we’ll be more experienced and skilled:)
I have to say, if the engine is in quite low mileage, it doesn't make sense to spend another 4000 Euro to renew all the parts, as some one mentioned above, original is always the best, shining piston doesn't help in anyway for the power and reliability actually.
Bonjour
J'ai une question...le moteur que vous avez installer est un 90 chevaux ou 110 chevaux ?
Thnx
Compression and a turbo...... You won't know what to do with yourselves! I have a 2L aircooled squirrel in mine 😄.
Haha!! It sometimes felt like a squirrel driving with the old engine too😉
Is it an oil cooler on the side of engine? I also have the AAZ installed in my T3, but didn’t refurbish like you. When is next video?
You’re right, it’s an oil cooler. We have been waiting for a new diesel pump forever, and now that we got it, we’re away during Christmas. We’ve set a date for the install in January, but there will be videos (not related to the engine install) prior to that
I have a AAz enging and a transmission vanagon 1986. I need the installation kit between the enging and the transmision with the bell housing and the enging supports . If some one knows where i could find it? Thank you
What flywheel and clutch do you use?
What kind of repair shop is that where you can chip in and help?
It’s at a friends place :)
Hei, bruker dere dieselpumpen fra AAZ eller JX?
Hei! Vi bruker JX, hovedsakelig fordi vi hadde en nyrestaurert pumpe og vi ville unngå å tilpasse motorluka. Ser i etterkant at JX-pumpen virker noe «underdimensjoner». Virker som at bilen ved konstant pådrag i oppoverbakke, ikke får nok diesel… Skal prøve med AAZ pumpe for å se om det hjelper
bonjour, je n'ai pas vu si vous l'avez mis, mais sur le AAZ remonter pour le T3/T25, il faut impérativement mettre un roulement a aiguille au centre du vilebrequin pour guider et supporter la queue de boite de vitesse, si vous ne le faite pas vous allez détruire le bout de la queue, le spi de boite et le refouloir, sur la vidéo, moteur sur la palette le roulement n'y est pas, vous devez mettre ce roulement ou une bague de bronze fritté, @+ sur le route peut être, pour moi c'est en syncro
Superb! What was the cost of all this? I had my engine replaced because of the cambelt snapped off. Bot now, no mechanic seems to be able to adjust the dieselpump properly :-O It has broke down a number of times! So sick of it. Mine is not a VW Caravelle, mine is a 1997 VW LT 35.
Roughly $4000, but that’s with lots of work/help from friends. Doing it at a garage would be way more expensive naturally
@@SimonBraeck I would say thats what I have paid so far in Sweden ( 40 000 SEK). Unfortunately one of the Swedish car inspection companies here have fooled me. When I bought my van for a little more then 1 year ago it had newly passed the inspection with 0 faults according to the document. The guy I bought it from told me that he knew the guys that worked there, but I didnt think much about it. This fall, on my first inspection with my van, it suddenly had 12 (!) faults on it. I was on the same car inspection company, but in another city. I have done only 7000 km. There is now way that all these faults came up under my ownership. This will cost me a lot of money to repair, and I have opened a case at ARN (consumers right). I hope I will have some luck getting some money back. Good luck with your new engine and thank you for your amazing videos!
Why didn't they paint the valve cover?
Is it rude of me if I ask how much this engine replacement cost in total?
@@bonjovi6829 You are probably right
4000 and counting! New diesel pump is not cheap😂
@Simon Braeck WOW
Keep in mind that we’ve replaced almost every part of it and had to pay a garage to remove the old engine...
Is it expensive to make or repurpose an engine?
Greetings from Turkey.I want to replace the engine of my air cooled 2000 t3. water cooled. which engines are suitable from the Volkswagen group. Which is the most successful? I would be grateful if you could help.
Not sure if it would fit but maybe an ALH would have been better, mechanically more reliable
A bit late now I’m afraid😄
@@SimonBraeck The AAZ is simpler, so you'll be fine. I had this engine and it was great!
art adrian generally I agree mechanical is better than electronic but electronic high pressure fuel pumps controlled by ecu rarely fail and rebuilding a mechanical injection pump and setting timing is not easy
I was wondering why you choose a old diesel (euro 0) engine, instead of a powerfull petrol engine? This because of the low emision norms in many European city’s.
Greetings from the Netherlands .
Because it’s the easiest conversion and with our skill / budget it’s what we ended up with :)
And reliable mechanical diesel with good fuel economy
U can steel it with 2 wires
What year is your van?
1986 :)