JX to AAZ conversion - a question of manifolds

[vantheman]

Hi Guys

Having the two engines side by side I decided originally to go down
the JX inlet/exhaust /turbo route for the sake of simplicity

However having found that the JX turbo is duff I have to revise my options.

Simon Baxter has suggested mating the AAZ turbo with the JX exhaust
manifold which allows the use of standard exhaust pipe and not having to
hack the engine mountings .

This appears to be satisfactory but which inlet manifold do I use?

On my Ebiza AAZ type engine,( I say type because although “1.9TD"| is
actually cast into the block nowhere are the letters AAZ evident), there
is an Exhaust Gas Recycling system which integrates the two manifolds

Using the original JX manifold (which just contains an air dump valve) suitably
fettled to match ports would appear to be the most straight forward solution,

However will abandoning the EGR system cause a problem with engine
operation or cause problems with MOT emissions testing?

On a completely different matter, on examining the bottom crankshaft drive
pulleys on both engines these appear identical.
Since many of the postings referring to this particular upgrade have
mentioned specifically changing over these pulleys and particularly renewing the stretch bolt.
Have I missed something?

Your advice is much appreciated

JBW

[Anonymous]

I'd use the JX inlet manifold and blank off the Gas recirculation valve, they're more trouble than anything else and it'll hardly make any difference to your MOT. Diesels are not tested at tickover in an MOT, only on full thorttle.

Re-crank pulley, whatever you decide to do here, make sure you tighten it fully.. check in the book, its more than you'd expect!

MG

[MacWilliam]

I'd use the JX inlet manifold and blank off the Gas recirculation valve, they're more trouble than anything else and it'll hardly make any difference to your MOT. Diesels are not tested at tickover in an MOT, only on full thorttle.

Re-crank pulley, whatever you decide to do here, make sure you tighten it fully.. check in the book, its more than you'd expect!

MG

Top class advice. My engine runs lovely in that configuration .Look on the flat near the oil filter support thingamybob for the aaz number.

[Simon Baxter]

You can't use the JX inlet manifold as the shape of the ports are different.
You have too use the AAZ inlet manifold and make a simple oval blanking plate to cover the space left by the redundant EGR valve.
You could "Match port" the JX manifold to suit but last time I looked there didn't look to be much material to play with.

JX ports are oval.
AAZ ports are "D" shaped.

There is a thread about it somewhere.

[Simon Baxter]

You will also have to strip the turbo and make the the oil come in and go out at the right angles, make a new oil feed pipe and oil return pipe.
You'll probably need the threaded adapter from the oil return of the JX then use one of my oil return line kits along with a block bung.

[MacWilliam]

You can't use the JX inlet manifold as the shape of the ports are different.
You have too use the AAZ inlet manifold and make a simple oval blanking plate to cover the space left by the redundant EGR valve.
You could "Match port" the JX manifold to suit but last time I looked there didn't look to be much material to play with.

JX ports are oval.
AAZ ports are "D" shaped.

There is a thread about it somewhere.

With all due respect Simon, I have doctored the jx manifold as you are hinting and it does work. Ok the conversion is only 2500 miles old and my experience in the field is quite limited and there is indeed not much meat left on the manifold once the op is done and most of the info on the matter i got from you,.....but it does work And the power increase is well worth the hassle.

[vantheman]

Thanks for the prompt feedback

My decision on the manifolds is on hold as I have a problem indexing the
AAZ turbo.

I realised that in inverting the AAz turbo onto the jx manifold the
body of the turbo would need to be indexed at least 180 degrees to
correct the oil feed positions.

To check how to do this I loosened the 6 bolts on the duff JX turbo
and eased the horseshoe clamping plates and with a small amount of
force managed to get the two castings to contra rotate.
Unfortunately this seems to have jamed the rota, moreover even
though the two halves rotate they don't appear to want to seperate.

I have loosened the same bolts and clamps to the aaz turbo but the
two halves remain solid and I am loathe to exert too much force in case
of damage. Even if I manage to move them is the rota vunerable and
can I seperate the two halves.

Any advice is welcome

JBW

[Diamond Hell]

Large it with PlusGas all over the offending item. It's not new and it *may* have been subject to many many repititions of heat stress over its life!

[Simon Baxter]

You can't use the JX inlet manifold as the shape of the ports are different.
You have too use the AAZ inlet manifold and make a simple oval blanking plate to cover the space left by the redundant EGR valve.
You could "Match port" the JX manifold to suit but last time I looked there didn't look to be much material to play with.

JX ports are oval.
AAZ ports are "D" shaped.

There is a thread about it somewhere.

With all due respect Simon, I have doctored the jx manifold as you are hinting and it does work. Ok the conversion is only 2500 miles old and my experience in the field is quite limited and there is indeed not much meat left on the manifold once the op is done and most of the info on the matter i got from you,.....but it does work And the power increase is well worth the hassle.

You've done it, I haven't, just going from my experience, when I looked I didn't think there would be much meat left, considering it being under pressure also. I just didn't want to go saying "yep, do that" when I can't qualify what I am saying, thats all.

[Simon Baxter]

Thanks for the prompt feedback

My decision on the manifolds is on hold as I have a problem indexing the
AAZ turbo.


....though the two halves rotate they don't appear to want to seperate.

I have loosened the same bolts and clamps to the aaz turbo but the
two halves remain solid and I am loathe to exert too much force in case
of damage. Even if I manage to move them is the rota vunerable and
can I seperate the two halves.

Any advice is welcome

JBW

Duck oil and leave to soak. give it a whack in a few hours!

[vantheman]

Many thanks for your replies everyone.

Have put the Turbo on 24 hour soak and will report back

In for a penny!

JBW