Club 80-90 Forums

Looks quite tidy. You don't have the breather on the side of the block that hydro engines normally have. No harm in adding this and it might help encourage oil return flow from head to sump.

If you've got oil going into the exhaust, where else can it be coming from except the turbo ? In the photo's you can see oil apparently weeping down the turbo exhaust casing.

Have you checked the return line is flowing free?
Oil is pumped under pressure to the turbo but if it can't get back out again it will force it's way past seals.
Is that rubber pipe up to the job? rated for hot oil? it's usual to use stainless steel overbraided teflon.

Thanks for your help. Been busy trying to get this sorted...

Got fitted: rebuild JX turbo (from CR turbos), new oil return line, new oil feed line, new down pipe, new exhaust, skimmed exhaust manifold, fitted AAZ crankcase/rocker cover breather (previously had the one with just one line going back to intake before turbo, new one has 2 lines, 1 back to block and other to intake.

Put 4.5l of oil in, started it up with all my fingers and toes crossed! Still same problem!! Turbo oil seals have NOT gone yet but the exhaust side of the new turbo is soaked in oil (which happened before last K03 turbo blew its seals).

Anyone got any ideas? I've got holiday booked in mid June and need an engine working!! I'm at a point where I now just want to pay someone to put in TDI engine or similar. Anyone knows who is able to do this before 15th of June?

David.

Have you got an oil pressure gauge on the filter flange ? Be interesting to know what pressure is being seen by the turbo.

Did you fit a new oil pump ? I know they have a pressure relief valve but I've no experience of one failing or the consequence of that.

Yep, oil pump was new when I first put everything in a bout a month ago...

Got 2nd breather pipe that runs down side of block.

Oil return looks clear, hard to tell. Oil return pipe is hot so oil must be going to it. How can I check that oil is returning back to sump/leaving the turbo properly?

I'm so confused... I'm at a point where I just want to pay someone to sort it out but cant find anyone.

David.

What about the oil pressure, have you a gauge ? Was the engine opened up or was the head left on ? What part of the world are you in ?

No gauge at the moment. Its on the ever growing list...

Engine was opened. Bottom end was checked and crank pulley & bolt was changed. Cylinder head was changed for a old one was cracked. Same valves & guides were put back as they were deemed OK. Pretty sure the JX oil pick up pipe was fitted back, either that or the AAZ one was, dont think theres any difference between the 2. Injection pump was refurbed as well as the injectors, etc, etc. Ive spent ££££ getting this far...Im heart broken!

It would seem that it may be oil is not returning out of the turbo but cant figure out how/why.

After 3 years the vans pretty much done apart from the engine So close yet so far!

I'm in Potters bar, EN6 (Hertfordshire).

Did you do the rebuild ? Are you 100% confident all the critical steps were done correctly eg. fitting head, cambelt, setting pump timing ?

Local old boy did the rebuild. He's used to rebuilding performance porsche engines and used to work on VW engine. Saying that my answer is no, I'm not sure it was all put together properly. As its taken me ages to get around to fitting the engine and with my luck, the old man has since retired and is nowhere to be seen.

Hence why I'd ideally like someone who knows what they are doing to figure it out...I just dont know many places that can squeeze this in before 15th of June. I'd also consider just converting to another engine if I can find someone to do that.

Simple way to test the turbo is to remove the boost pipe...if oil is emitted when running...it means its leaking...also engine should run clean at idle with the boost hose off...does it?

If that doesn't sort it take the breather hose off as well...these engines will run fine with no manifolds at all bolted to the head if need be...that will rule out pretty much everything not contained within the long block....so if it smokes then its either timing or internal.

Been scratching my head and moving bits around, taking things off to see what happens. No oil coming out of breather hose (one to inlet hose) even under load, turbo getting oiler as the engine is on and car is driving. It does seem that oil isnt draining from the turbo. The return pipe is at a good angle so dont think its that.

The engine does seem like it leaning forward, toward the front of the van. Its quite noticeable.. Wonder if thats got anything to do with it...

I've got no tool to do a compression test so I cant figure out if its the piston rings. The engine having being rebuilt, could it be that the rings take time to bed in so the wearing in oil makes its way past, ending up on the hot side of the turbo?

I'm well and truly stumped!

As the oil return angle is never great on a the AAZ when fitted in a T25, I've decided to get a new exhaust manifold made up to raise the turbo so the oil return has a steeper angle bac into the engine.

If I can get the turbo sitting high enough could the oil return then go back to the block as it originally was in the AAZ?

I cant think of any reason why I couldnt but I'm sure I'm forgetting something...

David.

I'm no expert but know that most AAZs running around have a similar oil return set up. Mine has been run like that for 30k miles, albeit with a braided metal (rather than rubber) hose from Brickwerks as described earlier by Baxter. I wouldn't be throwing more money at a new manifold if I were you.

I'm afraid I don't know enough to advise you further, but if it was me (and I couldn't find a local specialist) I would consider:
- mobile mechanic with diesel experience (I used one recently at £15/hr)
- get it towed to an engine specialist (there must be loads around that know VW TD engines - doesn't need to be a t25 engine conversion specialist?)
- look to buy a complete used but known JX engine (or maybe a 1Y 1.9D for simplicity?) to go on holiday (sometimes available as most prefer more power). Provided you have an engine hoist then engine & gearbox removal and reftting is not too hard. You can then get this AAZ into the back of the van and drop it to a specialist for bench testing at your leisure. You can sell the JX/1Y again later... Plenty of faffing but hopefully not too much financial loss...

TDis sound great (I'm considering when to upgrade), but they need a whole load more ££££ (gearbox ratios, intercooling etc), so it sounds worth getting this AAZ properly sorted as you've already spent plenty of dollar on it.
Good luck!

Ended up changing the set up and have manifold made already. Modded the air filter housing to fit and had alloy tubing made for turbo intake hose, as well

So far so good, turbo not covered in oil anymore, oil return lines flows freely albeit into the block rather than the sump, no smoke, etc.

Got plenty more poke and engine seems to be running clean. Only time will tell I guess...

http://db.tt/GKzOnm3w



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Well if that's done it then brilliant!! Looks to be a pretty good set up too. It looks relatively similar to how mine did with the original AAZinlet/exhaust manifolds (but with a much more professional looking exhaust downpipe!). Probably much better to get the turbo up out of the way anyway... Will keep fingers crossed for the roadtest!