Engine transplant

[H.Mc]

Hi All, ive read the wiki page and trawled endless pages on line but Ive melted my head by doing so. I have a 1.6 diesel CS engine in my van and want to fit a 1.9aaz turbo. ( which Ive brought) I just need a definate answer if the sump, enhaust manifold and airbox from the CS will fit or help where is the best place to source these items.

[kit]

Not done the AAZ but for the 1y you use the CS manifold sump and air box but remember to fit a spigot bearing.

[Bigjcc55]

You're sump will fit but won't have the fitting for the turbo oil return, you would need a jx sump or get yours modded, you will need the longer oil return pipe and bung for the block where it originally went.
You will also need a jx exhaust manifold, and mount the aaz turbo to it, I'm not sure about the air box tho.
There is a cracking guide on the brick yard for the conversion.
http://www.brick-yard.co.uk/vehiclespec ... ds/aaz.htm" onclick="window.open(this.href);return false;

[billy739]

you basically need the td parts not cs

air intake is completely different , manifold to filter!

as also said sump needs modding

you will also need the complete td ( jx) exhaust system including turbo and manifold

the jx ran an oil cooler which means you need the jx water hoses

also dont forget the AAZ will need a cooler stat / oil cooler fitting and make sure you refit the alt belt so the water pump goes the correct way

dont forget A NEW GEARBOX or you will still only be going 50mph flat out!


also worth noting that even with the 1.7 na & 1.6td jx VW fitted a deeper radiator and bigger cooling fan! - even vw had cooling problems with anything more powerful than 1.6 n/a engine!

[H.Mc]

Not done the AAZ but for the 1y you use the CS manifold sump and air box but remember to fit a spigot bearing.

Thank you Im sure |I will get there in the end!!!!!

[H.Mc]

Hi All, the AAZ is finally coming together............ after lots of head scratching and forum searching, Im just getting the static timing of the turbo done. Can any advice me on the clutch I need... Im not replacing my gearbox as Ive already recond that. I have part number 068 298 141 DX ( 110 ) but I cant find this clutch. I dont want to end up with a rubbish one. Anyone know the best Clutch to fit. Thankyou Helen

[billy739]

standard t25 diesel flywheel

cs/ td /1.7 all the same standard clutch

only change if you go tdi route but you need different input shaft for the box

[Plasticman]

whjat billy said about the box was not the condition of yours but the overall gearing so you will be revving the kn uts off it and economy and such will sufer, also you will need the support bracket for the turbo
do we get pickies of this as it progresses ?
mm

[H.Mc]

Hmmmm pictures than means being techi... i can try. thanks for the help im sure i will get there in the end. How do I know what input shaft it needs to be... sorry havent done this before. I have a cs recondition gear box ( in 2011 ).

[billy739]

keep your standard input shaft , changing it is for a more technical setup!

its good you have a recon box , but not sure if you understand , the new engine will still only let you go 50mph without damage tothe engine . it will however get there quicker!

to be able to use the new power you have in your engine , ie drive at 65 mph you need to change the internal parts of the gearbox

do you know the code of your box ( you should if its been recond)

basically the 1.6d van was able to (could just) drive at 55mph flat out based on max engine rpm
fitting an AAZ still means the same top speed , 55mph , you may get a few extra revs and say 60mph but you will overheat / damage your engine!
you need to change the internals of your gearbox so it is reving less at say 55mph as it has power to move the van

[H.Mc]

Thanks for the advice. It always helpfull to hear. I will sort the clutch today and hope to pick up engine tomorow.

[H.Mc]

Ok now im nearlly nearlly there, any one else done an AAZ conversion and needed a flue pressure pump??? engine ticks over but it you use the diesel primmer gently it runs sooooo much better.... Also what air intake set up have people used.... Im aware I dont want to be too near the exhaust??? We havenet cut any corners and Im so looking forward to the van being back on the road. Fingers xd Hx x