Alternative power-plants and transplants (GTi, Porsche, Subaru, Audi, diesel etc). Discussion and Q&A last answered over 2 years ago.
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Hi ive finally got my aaz in last weekend and after a minor starter motor problem it fired up! sounds ok and not much smoke ( bought off ebay already removed from car and done 130k so wasnt sure what to expect)
just 1 or 2 things..
Ive used all aaz manifolds/turbo set up.
The EGR. After reading up on here im better off without it so do i just remove the stainless pipe and blank the ends off leaving what i assume is the BOV? or can i remove that as well?
The exhaust. its still te piece of pipe off the golf hanging down! sounds quieter than the cs did though. Will any silencer do ?( ive read no back pressure can damage turbo)
Water pump. Does an electric water pump help cooling much? if so where will it fit and where can i get one?
each end of the EGR there is a large oval/diamond flange - connected with a stainless corrugated tube . take off completely and use gaskets to make blanking plate from - fitter at work made mine from 2mm steel - leave rest alone.
once you take it off give inards a bloody good clean - especially where it bolts to the manifold on the 1"high casting , mine has all this bit filled with carbon/oil/soot/"pooh" and was gopping.
i took the AAZ downpipe , cut off ALL the pipe , got it centre bored to clean up flange , cobbled/fabbed one using JX exhaust (bigger bore than AAZ ) and generic bends from motor factors.
standard water pump is more than adequate otherwise VW wouldnt have used it.
did you fit a new waterpump , cam belt + tensioner before you put it in ?
Cheers Elvis will be hacksaw job for me with blanking plates!
My plan for the ex pipe was to have a short downpipe and silencer going straight out the back hanging it on the l/hand orig. silencer mount somehow but i suppose 100 quids not too bad for a new jx system and doing similar to yours.
I fitted new water pump impellar, cam belt/tensioner also oil pump. Is belt tension critical or is the "pinch and twist no more than 90 degees " method accurate enough?!
Mentioned water pump as i recently saw t25 elec water pump on ebay but thinking about it my cs engine temp stayed constant ( till the head gave up!)
im no mechanic and have done 2 with the "pinch and twist" and appear to have worked ok. my tensioner tool was 2 nails in a piece of mahogony!!!
you put in the JX oil pump ? sits deeper than the AAZ . have you swapped dipstick aswell? make sure you calibrate it properly.
Ibought a pump from jk which was a shadek one but the feed pipe to pump flange fouls the crank on the aaz which i found out after fitting the sump!! rather than grind 5mm off the flange i bolted the cs/jx feed pipe to the new pump. seemed to sit pretty close to sump bottom.
I refitted my orig. cs dipstick with a few small o rings where it sits in the block to make a snug fit. put 4.5 litres in ran the engine and dipstick registered on the " min" mark. ideal!
