AAZ install /turbo hitting mount?

Post by **caveman** » 17 Oct 2008, 15:13

Those of you who have installed an AAZ into your T25: how many have fabricated a new l/s mount and are those who have done it by changing the exhaust manifold?

Post by **ringo** » 17 Oct 2008, 16:18

I used the JX exhaust manifold so it fits fine.

Elvis on here (but he's mainly on Brickyard) fitted a AAZ exhaust manifold. I dont recall him saying he had to make any modifications apart from fabricate his own exhaust.

Might be worth dropping him a PM but dont expect a response too soon as he's due a baby....

Good luck

Ringo

Post by **caveman** » 17 Oct 2008, 20:53

Okay that's good news. I've had couple of people here who have done the conversion and they tell me "just fab one up like i did" .Then i go and look at what they did and just cringe at the nasty rusty bits of flat bar which looks like it was welded by a monkey.

Post by **ringo** » 17 Oct 2008, 22:44

LOL - which bit was good news?

Ringo

Post by **Fully Loaded Cali'** » 18 Oct 2008, 11:06

Hi,

I'm in the middle of an AAZ conversion. Everything looks straight forward, just the Turbo position that bothers me. Does the turbo stay in it's AAZ position? Anyone with any pics?

Ian.

Post by **cabs** » 18 Oct 2008, 19:28

Hi

I am also half way through an AAZ conversion and have read many times on here to use the JX manifold for an easier conversion. Unfortunately I have been unable to source one so am using the original manifold. There is a problem with this as I found the waste gate actuator now hits the engine mount. To get round this I made up an extension piece and moved the actuator with only a small bit taken off the mount, it's a bit long winded but will hopefully work!!

Post by **caveman** » 20 Oct 2008, 11:47

I think those who have done it without a JX manifold should post some pics to show how they did it . i'm sure there are some well done ones so we can be inspired not to do a botch job of it.

Post by **ELVIS** » 20 Oct 2008, 12:30

I dont know if different turbos were used on the AAZ depending on the model/car it came from.
Mine is a fairly striaght fit and forget afair using the AAZ inlet/exhaust manifold. No fouling of engine mount/oil return line etc.

Obviously cant use the JX airbox due to the AAZ manifold sitting higher. 2 x SAMCO silicon hoses . one 90' connected to turbo and facing/angled towards the sidewall of engine bay- then using a aluminium connector - connect a 135' one onto the 90' the end of the 135' hose should sit square right into the recess behins the light. i then connected to a cone filter.
For the exhaust , take off the AAZ downpipe and carefully cut off the flange the mounts to the turbo . I then took it to a machine shop to be centrebored to have all the old weld/pipe cleaned out. Got a pile of bends/straights from Jetex and got a whole new downpipe fabbed that ran from the turbo (using the afore mentioned flange) all the way to the standard JX backbox.

As caveman says , take ya time and spend wisely (it wasnt big £) you end up with a neat install , not a pile of old toss.

Post by **HarryMann** » 20 Oct 2008, 13:26

I dont know if different turbos were used on the AAZ depending on the model/car it came from.

VW ones vary in minor (but possibly critical) detail... as well as the Seat Ibiza and Toledo ones.

If the wastegate diaphragm or actuator rod causes probs, you might be able to re-index the compressor Vs turbine side, see Wiki... Diesel for that. Might make enuff of a smidgin difference to clear...

Here is an idea for modding a main (l/h) diesel eng. mount, rather than making up a replacement, I prefer to modify the original as it retains the basic exhaust mount and accurate positioning of the engine Vs body, partic critical on the Syncros... although it lifts the engine about 1.5 mm that side!

https://club8090.co.uk/wiki/Pa ... gine_Mount

Post by **Fully Loaded Cali'** » 20 Oct 2008, 17:44

Does the turbo stay here then? I think i understand the reply from Elvis with the re-making of the exhaust. I pulled this AAZ from a Toledo, and just as the rest of the car was off to the scrap yard decided to cut the exhaust mount to the Turbo from the exhaust.

Post by **ringo** » 20 Oct 2008, 18:34

Can you use the JX turbo? Saves a lot of hassle. I used the AAZ inlet and the JX outlet - had to spend a bit on silicon hose joining the inlet to the turbo but it seemed the best combo. TBH, the jx inlet didnt look like it was going to cover the inlet ports.

Ringo

Post by **cabs** » 20 Oct 2008, 19:11

Hi

I have a different turbo with an integral wastegate.

Hence the long winded effort to be able to use the standard engine mount

Post by **HarryMann** » 20 Oct 2008, 20:16

Noyce one cabs, long winded hehe...

cabs AAZ mods

So, anyone here willing to sum up the gotchas, pros and cons of AAZ manifolds Vs JX... once 'n4all ?

Post by **HarryMann** » 20 Oct 2008, 21:41

Fully loaded Cali' wrote:and just as the rest of the car was off to the scrap yard decided to cut the exhaust mount to the Turbo from the exhaust.

Not sure what you mean there, the manifold?

You alos want to get the temp sender block connectors off before car goes away too... the ones for the coolant temp on side of block particularly, make life a lot easier, just cut the wires off at a reasonable length.

Post by **HarryMann** » 20 Oct 2008, 21:56

There are two turbos that are found on AAZ's..

KKK K14

Garrrett AirResearch T2

======

Both with same 4 bolt square exhaust manifold flange

The T2 has a separate wastegate actuator/servo

The K14 has an integral servo (cast finned)

IMHO, the Garrett T2 is more easily modded for servo position, having an external pushrod. The servo itself can be repositioned on the compressor case by drilling and tapping one or two M6 holes, as illustrated in the Wiki under re-indexing..

I've also had K14 exhuast sections leak at the CHRA joint...

Howevere, some like the K14 more and there are probably 9 times as many about as the Garret's on JX's and AAZ's.

have found the G T2 on Seat Toledos!