Club 80-90 Forums

I have had a rebuilt turbo fitted to my van which has a 1.9td aaz engine about four weeks ago, looking at the turbo last week I saw it was leaking oil, the engine had also got a bit smokey again, so I sent it back to the place where it came from, they have checked it and say the seals are perfect on it , so why is it leaking oil? The oil feed pipe is new and we blew the return pipe out with an air line, the return goes to the sump, I have seen some on this forum returned to the block, is this better? and if so where can I get the part to do this?
thanks in advance,
Brendan.

You could check the crankcase breather and make sure it's clear

Thanks, where is the crankcase breather?

From top of rocker cover you will have two pipes from the mushroom, make sure these pipes are clear and the mushroom itself

My van has only got one pipe coming from the top of the rockercover, it goes to the air breather intake going to the turbo, we disconnected it from the air intake, closing of the hole, and put a longer pipe on it coming from the rockercover, venting out at the back of the engine just in case that was causing a previous problem which was oil getting into the intake. Exactly how much oil should I put in the AAZ?
thanks,
Brendan.

Oil capacity is 4.5L. Did re-routing the breather sort your previous oil in the intake problem, or did you get the turbo rebuilt to try to cure it?

When you removed the turbo was there oil in the turbo housing ?

there was a lot of oil on the cylinder head side of the turbo so I figured the seals on the turbo were gone, that's why I replaced the turbo, I by passed the air breather just as an additional measure, is 4.5 litres with the oil filter empty or full? Thanks.

4.5 l with the filter empty. Was the oil inside the turbo housing or the outside ?

The 1.9 (1Y,AAZ etc) engines are 4.3 litre including the full filter according the manual!
If you are following the 4.5 litre 'advice' you are overfilling it. Get the correct manual for your engine and then you will not need to guess at things. A Haynes is cheap enough.

But an AAZ conversion uses a JX sump so I think that might be why 4.5L is recommended by most

Well I run my 1Y at 4.3 litres including filter with the standard 1.9 sump gasket and it is perfectly OK - no pressure drops, no frothing apparent. OK there is no turbo on it but it has the standard 1.6 sump and oil pickup. I would be inclined to run at the lower amount to see if that is a cure.
4.5 plus the amount in whatever size filter you are using does seem to be too much. Good chance that you will get frothing if you aren't using the baffle gasket.

I thought he meant 4.5L total? Thats what I read it as anyway

The oil was inside the turbo and on the air intake pipe.

I am not certain what my engine is! It was sold to me as an AAZ which had been in a Dutch golf which was written off over here and kept in storage for ten years, however, when I started to fit it, it would not fit, the holes for the engine mount on the oil filter side were in the wrong place and had one extra hole, I had an engine mount custom made in order to fit the engine. I sent a photo of the engine mount to Brickwerks and from some markings on it they said the mount was from an Audi, but they had never seen anything like it on an AAZ, so, it's a mystery! Any thoughts anyone?