Air box / AAZ conversion?

[v-lux]

Do most people use the JX airbox with an AAZ conversion?

If so is the normal procedure to relocate it to the other airvent?

Reason i ask is that once ive done the conversion i'm intending on charge cooling which will obviously need to be squeezed in behind the light cluster as close to the turbo as poss, which in turn will mean the airbox will have to go to the other side of the van.
All ok so far, but with a syncro diesel, the battery is in the engine bay and i'm thinking its going to be quite hard to get the JX airbox, and the battery into the recess...?

Anyone got any pics of this kind of set up?
Or suggestions as to the location of said items?

Also, i think my turbo is shot so im thinking of sourcing another one for when the new engine goes in. What are the options out there for alternative turbos for an AAZ running the JX manifold? something with a bit more ooomph perhaps

[Aidan]

Alan, you can use the AAZ inlet and turbo, but would need to make some exhaust bits and sort out rest of inlet side, and you would lose the jx airbox...Mike Ghia has done this and would be a good person to talk to, contact him via brickyard, or I can give you his number

[HOT 1200]

Hi...
I run a 1.9 tdi.........with JX air box....well its a round cylinder to be exact!

Fits behind the L/H rear light cluster with no mods......

GaV

[ELVIS]

does fit in with no mods , but................................
the 'inlet' side of the airbox will nearly be touching the bodywork-if you have inlet facing up it is touching 'roof' of the recess area behind light , if you lay it on its side its gonna be drawing air from the engine bay that has been heated by the exhaust!!!
an easy aand cheap fix

get a second airbox .(you could do it with just one if you get a small square of thin steel though)

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... box008.jpg[/img]

cut out 'inlet' stub (in pics look smaller as it further from camera)

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... box013.jpg[/img]

plate over with square you cut from a second airbox ( right guage steel and same coulour and was at proper price -not 'scene' price )

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... box015.jpg[/img]

move stub to back , loosely bolt to drum and use hole cutter. (DONT rivet before you cut hole as you wont be able to seam seal properly and all the filings will stick to the seam sealer)

de-burr edges , good coat of black seam sealer , rivet , wipe excess off

ET VOILA !

there is a plastic inner piece that sits over filter and under 'inlet' stub to even distribute incoimg air - pull this out and re-orientate it to match new position of stub- obvious when you look inside!

now the airbox inlet stub sits straight inline with the channel/flow of air coming from rear vent.
if ya dead clever , left over you will have a stub and loads of black ,curved steal you can post to ya mate in exeter to do same job (if he PMs you)

[v-lux]

Nice job!
Looks very tidy.

Buuuut mines a syncro and has a snorkel in the rear vent that attaches to the filter cylinder via plastic tube with various corners on it that runs in behind the light cluster.

Theres also a fan mounted in there that blows air over the turbo to help stop coking and as mine still seems to be operational, ive decided to keep the set up which means i wont be able to fit a charge cooler in there anyway.

Having looked at set ups in other vehicles, as long as the tubing is kept sensibly routed/well insulated i'm thinking that positioning the chargecooler on the other side of the engine bay should be alright.

Thoughts anyone?

Many thanks for the offer Elvis much appreciated!! You never know, once ive got the lump in the van you might find i take you up on the offer

[ELVIS]

no worries - think all T25s had the snorkel affair fitted - you gotta dump it if you put the box behind light , just not enough room! will keep bits just incase then

[sdelasal]

Thread from the grave! Did the van with a turbo 1.6 JX as standard come with a snorkal then? I'm putting such an engine in - repalcing the CS unit. I was hoping to re-use the snorkal. I have the jx airbox & pipes but can't figure out how it all goes together - are there any pictures available anywhere? Steve

[jebiga41]

put mine on top of engine bay on the left hand side only needs two 3"holes drilling and a bit of extra piping to connect it up will post some pics when i get a chance al

[slobbo]

I went for a bigger turbo on my AAZ and wasn't really impressed with the performance over the original. Ended up upgrading to a TDI. Was happy with result but not with the emptiness of my wallet afterwards.

[jebiga41]

Just for you al

take the air filter out

two 3 inch holes cut with hole saw

used original parts as had some lying around and also an air intake that was of the aaz i think but could use silicone and ally tubes and feed into the original air supply to the turbo


had to cut the snorkel thingy in about half (an old one lying around again and trimmed back the insulation and wire inside so would fit on the bits and sealed it up with gasket sealant on the inside

all done simples

room for chargecooler
hope its of help have my air filter now hidden in my westy cupboard but you could easily build a box to cover it (with your stainless screws )or leave it as it it?? found it to be an easier and neater solution to moving the battery (difficult and scary to be drilling holes in a bulkhead with a plastic fuel tank behind it !and doesn't infringe on storge space under the bed) and you get to keep the turbo cooler in the original place

[sdelasal]

Thanks for the picture - is your first picture showing how it is installed as stock? I had assumed thatthe cannister was mounted behind the near side rear light. STeve

[v-lux]

Nice one paul, tidy. (cant believe this thread has got resurrected!)

Only problem i've got now is the drawers, you know, the ones we were musing over at Mammut park. Ive decided they are such a good idea that im going to build some up. Which would mean that i cant put an air filter in that position.

However, ive got a K&N apollo filter which i 'think' i might be able to fit in next to the turbo cooler fan, leaving enough room in the engine bay for the chargecooler. (my chargecooler looks as though its almost identical to yours Paul, pace 4 core unit)
The only thing that concerns me about this solution is that i will lose the precleaner/dust trap from the JX airbox. Been looking at tractor precleaners with a view to mounting one somewhere else but would rather not have it sticking out the air vent, i'll only bash it off. Might be able to mount it on the underside of my roofrack which would protect it, but the piping would still be coming out the vent and past the gutter...

The precleaner that VWclassic had at Mammut park was a rather interesting solution i thought, (anyone see that?) Cant imagine they would be cheap though. Anyone good at plastic moulding at all...fancy a project?

[jebiga41]

Why not mount the original airfilter on the roof will probably fitt flush with the roof rack ? Instead of ging through the side vent just go straight up on the inside of the van ? Also works as a snorkel, and could be made out of plastic tubing .Could also build in an airscoop underneath the roofrack with a built in drop filter where the air has to hit a wall and have a trough at the bottom (look at Jaegers rally van)? Also air coming in at that height has less debris and so is cleaner especially in desert climates. Or could even have a half drawer to the front on the bottom and the airfilter where i have it although don't think it would take up that much space maybe 1/4 of the drawer? Ok you would part of the drawer but could still have another under or beside the airfilter? best thing to do is make a mock up air filter out of cardboard and play around with it to see wheres good ? Let us know how you get on