AAZ / JX What has it cost you?

[Iceworx]

I was wondering if you have had a JX AAZ fitted/ done it yourself What sort of money its cost you.

I am just trying to see how feasible it is to do the upgrade.

If anyone has a breakdown of prices , or just a total figure of what its cost them, i'd be very grateful!

Thanks

Chris

[HarryMann]

From nothing much (a new clutch maybe, Baxter's conv. kit and needle bearing for the input shaft), a slight 1" diff in engine height (turbo support bracket)
But in your case wouldn't you need to raise the gearing a bit, what is your gbox code and FD ratio?

Fair bit of info above, in Wiki and a lot on Brickwerks/yard.

Is yours really a 1.6D or TD (JX?)

[v-lux]

Cost me about £600 all in i reckon. (the first time )
But i installed it myself, and replaced almost all the seals and gaskets

[Fully Loaded Cali']

Cost me about £600 all in i reckon. (the first time )
But i installed it myself, and replaced almost all the seals and gaskets

£600 quid!! What did you buy for it? Apart from a new clutch and cam belt there is no more real cost to it. The exhaust gaskets are only a quid each, the Inlet gasket is £4. Oil be about £20, other fluids about £20. Sump gasket £15 - I'm no where near £600 yet...even if I buy a kit from Baxter.
Have i missed something
Did you remove your Head sorry the engines Head?

Did you have a donor JX?

[v-lux]

Actually, come to think of it...
Realistically i reckon it was more like £900

Engine was £300 quid (had 80000 miles on the clock)
turbo... £300approx

The other £300 was spent on seals, gaskets, 'o'rings, oil, coolant, grease, oil pump, cam belt, alternator belt, clutch, spigot bearing, block bung, turbo return line, exhaust J pipe, oil filter, fuel filter, fuel lines, glow plugs, various bolts, washers, jubilee clips etc.
Paid a little to have certain things altered/fabricated also just because i didn't want to bodge it, such as, turbo support bracket, accelerator cable bracket, fuel pump lever arm.

There's probably more little odds and sods that ive forgotten.
But that's as honest a figure for what i spent as i can give for what i considered a worthwhile job.
I could've just stuck the engine in, but i was more than fed up with it being unreliable, i wanted to be able to trust it and for me that meant making sure i knew what the deal was with everything.

You get what you pay for....

Oh, and yes i did have a JX donor....a rather poorly one.

[HarryMann]

One key to this as Al says, is a good turbo... you can get lucky and find a refurb or good condition one on the AAZ donor, or pay from £150 (dubious) to £300 for a rebuilt one...

But if the turbo seals are poor, then not only will it be a bit smokey, it'll be reducing the oil pressure, just the same as it would on a JX

[ringo]

£900 seem more like it to me.

£300 for an engine with 88k is a bargain. I paid top dollar for a running vehicle and took the engine out - so i paid more like £450.

Stick in a new oil pump, water pump and bits and bobs (i had to spend £50 on silicon to join the AAZ inlet manifold to the JX turbo) and it soon mounts up.

I also added an oil cooler because i really didnt want to have to worry about hot oil under load. Thats was another £200 ish (for a big one with thermo plate).

My van is soo much better to drive now - but a £1000 better ?

Ringo

[HarryMann]

(i had to spend £50 on silicon to join the AAZ inlet manifold to the JX turbo)

If you mean silicon tube, I've spent twice that easily, but up to an intercooler and back... and it's definitley worth using good stuff!

£1000 better?? Of course Ringo, esp. with that oil cooler, all in all I bet you feel quite relaxed that she's going to last and any investment you have made is not going to go down the drain any minute

[ELVIS]

Actually, come to think of it...
Realistically i reckon it was more like £900

Engine was £300 quid (had 80000 miles on the clock)
turbo... £300approx

The other £300 was spent on seals, gaskets, 'o'rings, oil, coolant, grease, oil pump, cam belt, alternator belt, clutch, spigot bearing, block bung, turbo return line, exhaust J pipe, oil filter, fuel filter, fuel lines, glow plugs, various bolts, washers, jubilee clips etc.
Paid a little to have certain things altered/fabricated also just because i didn't want to bodge it, such as, turbo support bracket, accelerator cable bracket, fuel pump lever arm.

cam belt tensioner , sump gasket , water pump , thermostat , clutch (replaced as preventative as £90 on a clutch is a whole lot easier when the lump is on your garage floor!)
The list goes on. Go on GSF site (FFS DONT but all the stuff from there- thermostat esp.!!!!) and add up all the cost of the parts.LIKE THIS

11033B VALVE COVER GASK.SET-CORK T25 1.6 Turbo diesel 8/84 > 11/90 2.50 1 Delete

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98081A FUCHS UNI DIESEL 15W40 5L DIESEL/TD ENGINES NOT PD OR LONGLIFE 15.25 1 Delete

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15499 OIL COOLER T25 1.6 Turbo diesel 8/84 > 11/90 32.50 1 Delete

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BBGN857 GLOW PLUG-BQ T25 Diesel & Turbo Diesel 8/80 > 6.05 4 Delete

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13120 TIMING BELT T25 1.6 Turbo diesel 8/84 > 11/90 8.50 1 Delete

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11616 SUMP GASKET-CORK(BQ) T25 1.6 Diesel 1/81 > 7/87 6.50 1 Delete

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MMW940/25 OIL FILTER-MANN T25 D/TD ALL 3.85 1 Delete

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13135 TIMING BELT TENSIONER T25 1.6 Turbo diesel 8/84 > 11/90 11.50 1 Delete

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13314 FAN BELT-10x600 T25 1.6 Turbo diesel (With 65A Alt.) 8/84 > 9/88 2.50 1 Delete

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15307 OIL PUMP T25 Diesel & Turbo Diesel With Servo > 11/90 42.00 1 Delete

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13420 WATER PUMP BELT-10x643 T25 1.6 Turbo diesel 8/84 > 9/88 Water Pump Belt 2.75 1 Delete

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R-622020006 CLUTCH KIT-215mm T25 1.6 Turbo diesel 8/84 > 11/90 80.45 1 Delete

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02280 CLUTCH SPIGOT BEARING T25 Turbo Diesel 8/84 > 6/90 4.00 1 Delete

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17058 WATER PUMP-COMPLETE T25 1.6 Turbo diesel 8/85 > 11/90 15.75 1 Delete

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17642 THERMOSTAT T25 1.6 Turbo diesel 8/84 > 11/90 4.85 1 Delete

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28226 EXHAUST DOWN PIPE GASKET T25 1.6 Turbo diesel All > 2.75 1 Delete

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MMWK842/2 FUEL FILTER-DIESEL T25 1.6 D / TD > 7/87 5.70 1 Delete

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MMC13114/4 AIR FILTER-BQ T25 1.6 Turbo diesel 8/84 > 11/90 11.25 1 Delete

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98071 ANTIFREEZE-5L GENERAL USE 13.95 2 Delete

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TOTAL(exc. VAT & Delivery) £ 304.70
Delivery(UK) Free Delivery
VAT £ 53.32
TOTAL £ 358.02 !!!!!!!!!!!!!!

And thats not including stuff you find when the engines out - ie flywheel ring gear is worn to buggery, starter is falling to bits, clutch slave cylinder is leaking ,split hoses , knackered senders,exhaust , BAXTERS kit etc etc etc
Makes sense that when engine is out and in bits to do it once and do it properly.

For O rings/gaskets/thermostat go to main steelers.O rings are pennies each and OE quality.

You get the general idea at where prices are coming from though

[garyd]

I agree it is worth getting right the first time. Here is a list I posted a while ago of all the stuff I replaced during the conversion.

"and here is a list of bits I bought:

Fit new JX parts: Number Price
clutch assembly 068 298 141 DX (110) £63.50
Crankshaft spigot bearing 111 105 313 A £5.50
Sump gasket 044 103 609 D (18.56) £7.01
Oil filler pipe gasket 068 115 315 A £1.22
Sump drain plug seal washer N013 849 2
Alternator / water pump belt
Water housing 'O' ring 2no. 052 121 091 A £1.00
Exhaust gasket (turbo to pipe) 893 253 115 £3.73
Exhaust manifold to head gaskets. 4no 028 129 589 B £2.25 each
Heat shields - 2 parts 068 253 283 & 068 253 283 A £13.76 each

Fit new AAZ parts (engine no - AAZ 504 742):
Timing belt & adjuster 028 109 119 P & 068 109 2430F £20.00 & £30.76
Oil cooler 'O' ring seal 028 117 070 £3.77
Oil Filter 068 115 561 B £6.59
Crankshaft oil seals (Fr 068 103 085 E) & (R 068 103 171 F) £4.17 & £8.45
Crankshaft oil seal gaskets Fr 026 103 161 B & R 026 103 181 B £1.46 each
Crankshaft pulley end bolt (M14 x 1.5 x 47) N905 771 01 £1.37
Flywheel bolts 6no N902 061 03 £1.84 each
Inlet manifold gasket 028 129 717 D £4.19
Inlet manifold elbow gasket 028 129 754 A £3.25
Water hose - pump to cylinder head (AAZ) 028 121 053 Q (19.85)
Coolant Thermostat 'O' ring seal 038 121 119 B £1.48
Timing belt cover 028 109 123 E £15.97

4.5 litre oil
Longer turbo oil return pipe to sump (JX +1")
Bung to block (end of AAZ oil return pipe)

Prices in brackets are VW with aftermarket prices following."

Hope this helps
Garyd

[ringo]

£1000 better?? Of course Ringo, esp. with that oil cooler, all in all I bet you feel quite relaxed that she's going to last and any investment you have made is not going to go down the drain any minute

Im not quite there yet Clive I reckon a few more thousand miles and i may get content. I must say, it drives soooo well - i just need the confidence in its reliability.

The oil cooler gives me a lot of confidence - especially when i was having overheating issues (i knew the engine oil was not getting completely cooked even though the needle was going up).

GaryD and Elvis have brought up another expense which i forgot. Baxter bits. That oil return pipe is the nuts - but its another £50 which has to be budgeted for.

It all adds up.

Having said all that, you dont have to spend all that money - you can source / manufacture your own bits.....

Ringo

[HarryMann]

I seem to have twice been able to connect my turbo up with a std one... strange that, maybe a bit stretched

[Iceworx]

Mine really is the 1.6d not a JX..




I think i'll just look for a JX and do a direct swap

[ELVIS]

surely , even if you fit a standard JX you will still have most of the above outlay anyway ?!?!?!?

[Iceworx]

Likely, but looking at the spec on the AAZ and the JX the AAZ is only 5bhp more.

and looking at whats needed for the AAZ, compared to the JX, sounds a lot simpler.