Club 80-90 Forums

I know this isnt the right place on the forum but I'm desperately trying to sort my AAZ in my Syncro in time for my upcoming holidays so I'm putting this out to fellow Syncro owners as well.

https://club8090.co.uk/forum/viewtopic.php?f=12&t=115435" onclick="window.open(this.href);return false;

Any help welcome & very much appreciated.

Thanks, David.

where in the uk are you?

the turbo from the 1.6jx does spool up quite fast on an aaz, & does run out of puff fairly quick but should'nt at 2500 rpm, i suspect you have an air leak, so i would suggest checking over all your small vacuum pipes in the engine bay & also the bigger pipes from the intake to the turbo, also check the intake manifold nuts are tight

the other thing it could be if you have used the 1.6jx turbo diesel intake manifold is the factory dump valve, if the dump valve has gone a knacker which considering the age it may be letting boost pressure out to early

its more than likely just an air leak so easily/cheaply fixed

Thanks for the reply. I'm leaving work early to go check it out. I'll start with pipes & inlet as you said.

I'm based in Potters bar (Hertfordshire) but willing to travel (albeit a lot slower than I'd like).

I'm using new AAZ turbo (K03), AAZ inlet manifold, JX Exhaust manifold & exhaust (using Futbus kit to link it together). Injection pump has been refurbed and is the later style AAZ one (with the electric cables - which I'm only using one of them to 12v).

Turbo is new & all manifolds were machined so they should all be flat.

Still thinking I'd rather hand it over to a pro to make sure its all been put back together properly...

Thanks, David.

sounds like you have an airleak somewhere possibly only a pin hole that opens at a certain pressure do you have a boost guage fitted ? mix up some fairy liquid and water and try revving it might show up where its leaking or could be your wastegate sticking but if its a new turbo its shouldn't be.

as said by the chap above from dublin possibly a sticking wastegate also as said above a small airleak that increases with pressure, inistially just do as above,

steal a bottle that gives a spray action from the kitchen cupboard, mixup a strong washingup liquid/water mix, spray it on the engine hoses/pipes & fire it up & look for bubbles appearing/popping

it may only be one loose jubilee clip that needs a slight tighten with a screwdriver, or a split in a smaller vacuum pipe

you could check the wastegate arm with the engine off by just grabbing it with pliers & making sure it moves, they only move 1/2 an inch or so, maybe less, it should have a fair amount of resistance but move smoothly, i'm no pro i'm in the midlands i may know somone down your way a pro that could check it over i'll hoax his number out..........them pm you the number hold tight

when i did my aaz conversion on my t25 crewcab doka i used the old 1.6jx turbo, it spooled up & went like a rocket around town but on the motorways it was a bit weak but sufficiant JUST

i know its a bit of a chavvy vid but if you are handy with a bit of plastic pipe a drill, some araldite glue & have a small compressor this is a great way to jeck for boost/air leaks without running the engine

http://www.youtube.com/watch?v=atretf9u-Mc" onclick="window.open(this.href);return false;

Thanks for the advice.

I'm officially sad

Seems that things have gone from bad to worst!

I'm now pissing oil out of the exhaust (tailpipe & exhaust joint) and getting LOTS of fluffy white/light grey smoke.

I'm inclined to say its the turbo but I dont want to start blaming the turbo straight away as could be from CCV going back to inlet before the turbo, could be oil return line not quite right, etc.

Do people's AAZ have the CCV/rocker breather valve with one outlet or two? I've only got the one going to the inlet hosing that connect after air filter but before the turbo. I see some AAZ's have 2x connections and wondered if I'm missing something.

David.

How much oil did you put in it?

I've put 4.5 l in with new filter.

I'm going to plumb rocker cover breather hose into a bottle to see how much comes out.

Anyone know if a rebuilt engine should breath a lot more/harder than standard?

I'm clearly out of my depth with this engine conversion...

Knew I should have gone TDi...

If you're using AAZ turbo and manifold, did you re-clock the turbo for its new mounting angle ? Most folk would just use JX turbo/manifold which seems to be a tried and tested combo on the AAZ as the oil drains the same as it does on the JX. Could be a duff turbo of course, it has been known for 'recon' turbos to be no good.

Thanks everyone. All your help is very appreciated.

Think I'll try sticking old K14 turbo from the JX on there to see what happens. At least that way I can rule turbo it out (or not). Just need the JX oil return line I gave away a week ago....and to empty the oil from the exhaust as I think theres a fair bit of it in there.

I've taken the rocker cover breather off and there isnt silly amounts of oil in the hose to inlet hose so I doubt its from there, might add steel wool to rocker breather and extend it out a few inches as recommended by Baxter in a post I've seen somewhere. The oil return pipe is a tad too long so curves in the middle a bit and may not help with draining, guess this will be sorted out when I change turbos. Current Turbo (K03) inlet is more at 2 o'clock than 12 but oil can still enter no problem so dont think its that.

I'm just hoping its not piston rings or anything that sinister. Lucky I've got 4 days to get to the bottom of this. And I was going to fit new carpets & interior trimmings this weekend.. I was looking forward to that!

Should AAZ engines have 1 or 2 outlets on the rocker cover breather?

My spare golf has 2x and I remember the JX had one.

The AAZ I'm having problems with only has 1.... Putting the engine in has taken me so long I can't even remember if I blocked the block up myself and accidentally used the JX breather or whether it was like that in the first place.

Can you post up some pics am getting confused regards the breathers there should be a breather from the engine block going to the "satellite" thingy on top of the rocker cover then a pipe from this into your air intake. Most peeps extend this so it goes over the air box to allow the oil to drain back to the rocker cover. Sounds like there's something amiss with your turbo as the lads have said might need to be reclocked or try and get a Jx's exhaust manifold and jx turbo hang in there the Aaz is a good conversion just sounds like you have a few hiccups with the install

Or you could have a blocked oil return to the sump from the turbo ?

dcfb77 wrote:might add steel wool to rocker breather

I wouldn't put any loose foreign bodies in there, could get clogged and prevent breathing, or get spat out into inlet tract and into turbo There are proper oil separators which wouldn't be a bad idea to fit, I've got one off a Sharan on my TDI. They fit between the outlet on the block and the mushroom valve on the rocker cover.

Sounds like you have oil leaking out the turbo seals to me, be hard for the amount you describe to find its way out the breather. Like Paul said, clear pics of your setup would be helpful.

Thanks. I won't stick anything in there. Probably a wise move.

Photos of current set up:

http://db.tt/LwCM794h

Oil coming out of exhaust is very dark grey if that helps... Beats me, I'm way out of my league with this.