AAZ fitting Qs!

Post by **ELVIS** » 13 Sep 2007, 18:46

righto just picked up me sooper clean AAZ ( thanx Diviy and Dean) . am going with keeping the AAZ inlet and exhaust maifolds and keeping the turbo as it is/was from factory . read loads n loads n loads . but couple of definitive answers just to put my mind at ease.

(1) is the stock oil pipe ok as it is if engine sits canted over ? the oil return goes into the block and not the sump.

(2) am i ok leaving the oil breather system as is ? there is a really thick plastic pipe just near the oil filter that vents the block + all the pipes on top , all ok to leave 'as is' ?

(3) the pump AAAAAAAAARRRRRRRRRGGGGGGGHHHHHHHH. yes i know there are millions of variants. mine has what appears to be the fuel stop solenoid + a second fuel stop solenoid and also on top near LDA teo wires that come down to a plug near the fuel stop solenoid , any ideas ? left finger points to what looks like a second stop solenoid , right one point to plug that has 2 wires , goes up past top of dipstick and goes under a cover next to lda and above throttle arm springs)

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... 007393.jpg[/img]

(4) i can see where the LDA gets a vacum signal from the manifold but ontop of the wastegate there is what looks like a blow off valve with an inch of pipe attached to it!!!! i cant decide if that is how it ois meant to be or it is ment to attach somewhere , if so , where ?????????(see pic)

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... 007395.jpg[/img]

(5) is it ok to take off/blank the EGR pipe ?

(6) where does the small bore vacum type hose from the EGR meant to go to ? was it to something that is still attached to the car
? what shall i do with it ?see pic

[IMG:800:600]http://i49.photobucket.com/albums/f262/ ... 007394.jpg[/img]

cheers elvis

Edited by ELVIS on 13 - Sep - 07 at 19:01

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Post by **HarryMann** » 14 Sep 2007, 01:14

Try to get you some answers tomorrow Elvis...

Other than of course the LDA is being fed a +ve boost pressure or atmos, not a vacuum

Think you can chuck all the EGr stuff, BOV exhaust usally goes down into the pre compressor inlet pipe on a JX, but I've blocked my BOV up anyway as boosting above 12psi (its normal setting, though you could screw it in a bit, has a setting screw)

Post by **ELVIS** » 14 Sep 2007, 20:42

cheers harry ! from vwdiesel.net sussed out most of wiring and also that lda is connected to the manifold - just like my SB . i think the EGR pipe is just a vent to protect the metal,stop it getting crapped up . dunno about turbo/wastgate pipe though ? gimme a shout if you find owt out! cheers elvis

Post by **HOT 1200** » 27 Sep 2007, 09:08

You can keep the standard AAZ turbo oil return.....
(My AHU engine has retained this set up)

Oil being fed to the turbo is under 'full pump pressure', It does not rely on gravity to find its way back to the block...However you should ensure oil can not 'pool' in the return pipe once the engine is switched off, so any slight downward gradient in the pipe away from the turbo is good enough.

You must also make sure you do not overfill with oil. This will kill the engine, not the oil return pipe.
Firstly, drain oil, remove oil filter....then fit a Mann oil filter for a 1.6td T25. They are bigger, much bigger! so when you fill your engine with 4.5ltrs of oil, the larger oil filter will hold more oil and thus you will have less in the sump which is what you want when the engine is sitting at 50deg....You then need to make a new Dipstick.....(longer)
(most people make the mistake of fitting a standard golf/passat oil filter, if you use this, then 4.5ltrs of oil will be too much......

GaV

Post by **ELVIS** » 27 Sep 2007, 09:23

cheers fella - just on way out to hopefully finish today ( taken 4 days now due to rain , work , training courses at other end of country and as i live in the middle of nowhere -everytime i need a part its a 2h round trip to town

) . to prevent 'pooling' i have carefully cut and deburred the hardline at the tubo end , done the same to the JX harline at the sump end - then joined them using quality oil hose from pirtek

Post by **HOT 1200** » 27 Sep 2007, 09:39

Good luck...Ive edited my post and updated important info about the oil filter......
GaV

Post by **ELVIS** » 27 Sep 2007, 10:00

cheers gav! any idea how i can get the AAZ dipstick holder/tube out so i can fit a JX one ? or is it best just to remark the aaz one ?

Post by **HarryMann** » 27 Sep 2007, 10:55

It does not need rely on gravity to find its way back to the sump...

To a large extent it does. Once through the turbo bearings and into the CHRA well, which is comparatively large compared to the pipe and the bearings' volume, the oil is effectively - 'on its own' to find its way back to the sump.

If it was relying on feed pressure, then the CHRA well would be permanently full, which is known to be an off-design and unwanted condition (by the turbo manufacturers). When it occurs through cornering or overfilling, all sorts of problems develop.

I think you'll find a lot of people have altered the feed return line from the block to the sump when canting the engine over, but its interesting that you haven't found it necessary.

Post by **HOT 1200** » 27 Sep 2007, 14:35

As long as the oil can run away from the turbo.....its fine.....you should see the 'strange' angles they put oil returns in on boats (I work with marine diesels) And in real rough Sea conditions, the engine installation angle is constanlty changing as the boat gets 'rocked' around in all mannor of directions....

If your lucky to enough to have a 'turbo' sump, then yes take adavantage of it and replicate the JX install. But to do this correctly, you will need to re index the turbo.....

GaV

Post by **HarryMann** » 27 Sep 2007, 17:49

True, and be particularlty careful re-indexing the KKK turbos, there is precious little for the 'C' plates to grab on the central assembly..

See Wiki Diesels Turbos for re-indexing information...

https://club8090.co.uk/wiki/Tu ... e-indexing

Post by **andysimpson** » 27 Sep 2007, 18:07

All depends on seals, few turbos have all required seals to prevent oil going into compressor, some old volvos and saabs were good for this but i don't now of any on modern cars. NO vw turbo has the seals and needs gravity to get rid of the oil.

Post by **HOT 1200** » 28 Sep 2007, 09:50

just like to add.....the turbo boost pressure also helps to keep oil out of places where its not meant to go.....thats why most worn turbos smoke at idle/tick over when there is virtually no boost.....

I dont recomned you do this, but if you remove the turbo oil return pipe and run the engine, you will see what I mean by the oil being forced back to the sump/block.....If you have ever had a slight leak in the return line, you will know what a mess it makes....oil sprays everywhere......!!!t not gravity doing that, thats pump pressure.....
but, like I said, if you have the JX sump oil return, extend it and use it.

Ive not had a problem withy my standard 'Golf' set up in the bus, but then I dont overfill the engine, I have the correct length modified dip stick, and run the proper super big Mann Diesel filter.
(by the way, dont bother messing around shortening the dip stick tube, simply make a new dipstick, much easier....... (three old Aircooled beetle/camper stickes does the trick, cut the handles off two o them and weld to third one with handle......(establish correct lenghth by using good qaulity (fencing) wire !
PM me for details......

GaV

Post by **Simon Baxter** » 30 Sep 2007, 21:34

You must also take into consideration that if the oil return is not as close to the vertical as possible that oil will sit in the bearing housing when the engine is turned off, a hot turbo and trapped oil is going to lead to burnt oil deposits building up in the turbo.
Theres a reason VW mounted the engine as they did, and they were carefull how they did it, to me not having the oil return as close to the vertical is daft, but thats me.

Post by **HOT 1200** » 01 Oct 2007, 12:07

"close to the vertical as possible "
Unfortunetly, I only have a 1.6d sump........my options were limited...although I did consider drilling and taping the Oil filler neck low down where it meets the sump......That said, the motor runs fine, lets face it, the main fear is high oil consumption, smoke, engine run away...

So far, Ive seen two people convert over to AAZ engines, both killed their engines within weeks by overfilling and venting the breathers into the induction system.(they took the trouble of using the JX turbo oil return but they did not modify the dipsticks......a costly mistake.......I learnt by their mistakes......modified the dipsitck and vented the crank case fumes to atomosphere (although my AHU produces very little blow by, which just shows you if you have crank case blow by problems, chances are the engines bores/pistons/rings are very worn, these engines dont acutaly breath heavy when in good health.

Also worth noting, AHU engine has totaly different turbo set up compared to 1Z........Manifolds/exhaust etc....

From what I have seen, the 1Z turbo is mounted very high up almost in line with inlet mainfold..........the AHU set up carries the turbo 'low down' similer to the old JX set up.........
The above info is based on a comparison between the AHU MK3 Golf and the 1Z of an AUDI 80........

GaV