AAZ engine & gearbox - Er...?

[talkingwhippet]

Hi - have recently bought a T25 camper with pop-top - A674 OVH if anyone knows it. Has a 1.9TD (AAZ) fitted with 4-speed gearboix (DU).

Couple of things I wanted to check out - whoever converted it didn't fit a spigot-shaft bearing. I've got one on order form Brickwerks, but wondered how much movement there should be in input shaft in gearbox? Have taken off bell-housing to fit new oil-seal (as wandering shaft has made old one much larger!). Input shaft seems to have some free movement - which I guess is normal - would be good to have confirmed.

Also, the oil return from turbo to engine. Mine seems to enter the block somewhere near the embossed 1.9D/TD stamp. Reading other info, should it really enter much lower in the sump itself? Is this what the conversion pipe from Brickwerks would do? If so, does this require drilling sump to make connection?

Finally, is it ok to use replacement bolts for driveshafts from any fasteners place, or should I be sourcing from VW or somewhere else? Knackered heads of several of mine getting them out to drop gearbox.

Many thanks.
Great forum BTW - helped me loads already

[Westy.Club.Joker]

You`ll need a turbo sump that has the boss on it for the oil pipe fitting to screw to, unless you are very good at drilling, tapping and probably welding a boss on to suit.

Not sure about how much wobble you have in the shaft.

[ELVIS]

my shaft is alittle wobbly! dunno if its to do with length of it , IIRC its only held in by a circlip (havnt changed it myself but remembering reading on here/BY) so it isnt as snug a fit then if it was in a bearing.
there is loads about oil return line on BY , its been discussed too many times! the tech answer is that the oil pressure is xxlbs , pump is forcing oil round etc etc etc so gravity dosnt come into it.
HOWEVER , my only concern was when the engine was turned off. by leaving the original oil return line in place ie goes to side of block the line is almost horizontal with no run off . I read posts from a few 'techy' type people that if the oil sits in the line it could leave carbon/$hite/deposits(all the poo thats held in suspension in oil) etc that could eventually build up and maybe eventually break away in lumps of cack. Im not a scientist that specialises in petro-chemical but it did/does make sense. In light of no petro-chemical engineers being on the forum to prove-disprove it was an extra 'safeguard' to return it to the sump.
less than a tenner for fitteings and hose from your local PIRTEK agent.

[Plasticman]

Drive shaft bolts, get from vw or torx from a bolt and nut company, must be high tensile not market stall monkey metal.
Mike

[Aidan]

input shaft should loosely wobble in the seal, it's not rigid, but attached to a m7 internal stud and then the sleeve locks the splines and the circlip keeps the sleeve in place. Excessive play and the seal will be worn and leak when full of oil.