2.5 AJT questions

Post by **Pat Dolan** » 01 May 2008, 03:40

Greetings from the Great White North

Been gone quite a while (working) and nearly zip has been done on our Syncro Westy project. We actually hired a full time mechanic to move along the dozens of unfinished projects, and just as he got the powertrain out of the T3, his shoulder blew out and we lost him for nearly a year. I expect to be able get back to this project in a month. The only good news is that I managed to buy an A2 Golf Country over the winter to keep me happy (until I can get a TD into it).

We have also located a small shop in BC that specializes in Syncro gearbox work to do the rebuild, LSD and re-gearing of the Brick, and we have the South African bellhousing and crossmember. The 2.5 pump is in Toronto getting converted to M-TDI with a 2.4 core donor.

Anyhow, my current concern is: the engine we have is an AJT. I think it was rated at about 90 HP, and has a tiny KKK K14 turbo - which we want to keep. We will add a 1.9 A4 CAC. We can get a lot more jam from the pump (Giles Gallie at Performance Diesel Injection in Toronto/Markham has done many), but don't want a race truck, just a bit more juice to haul the thing up the side of a mountain or two (hopefully while towing our bikes into the desert). What's the story with the K14 in this application? How much HP and/or boost will it tolerate before it melts down? How is the boost controlled (yeah, I will take it apart and look, but not at home so kind of difficult to do)? Forgive my incredible ignorance, but this engine was never sold here (nor ANY variation of 2.5 TDI) and I can't even find a shop manual (for which I will either kill or gladly send a bunch of hard-earned cash).

Will try to check in where I can get internet access, so don't be surprised if I dissappear for a few days. In fact, you can just look up and wave, as I should be overhead approaching AMS enroute ME if you read this in the morning.

Cheers - Pat

Post by **Simon Baxter** » 04 May 2008, 22:28

AJT engine is 88hp, it's from a '96 to '03 T4 (eurovan)
basically, your on the wrong forum, this place is for T3's, or vanagons.

You may be better here.

http://vwt4forum.co.uk/index.php?

Or here.

http://www.brick-yard.co.uk

K14 is different to the K14 fitted to T3 TD's, it has a different exhaust side.

Turbo is actualted via the usual N75 valve, although it isn't a VNT and does have a conventional waste gate actuator.

That same K14 was fitted to the ACV, which is the 102hp 2.5TDI also from the T4.
that turbo is good for about 170hp with a set of .216's from kerma but have a word with Giles as he will be more clued up on it I feel sure.

There is no manual worth buying for that engine, there is someone on e-bay that is selling copies of the Chilterns manuals but they aren't very good.
I do have ElsaWin, which is VW's electronic workshop manual if you need anything specific, or it maybe worth your while to search ebay.co.uk for autodata CD's, which are basically car data on disc, it's more than i need and I fix the things , well I won't say daily but weekly.
or, even buy Elsawin.

Is the pump that giles built the one where he test fires it on an engine crane? sounds brilliant if it is, I'm very interested in the mechanical pump he has built for it.
I would love to have a Giles pump on my van..

Post by **Simon Baxter** » 04 May 2008, 22:29

incidentally, there was another T4 2.5TDI, but that had 151 hp, the AXG, interestingly that had the same lower compression ratio of the AJT than that of the ACV (102hp)
Seemingly the better base for big HP.

Post by **Simon Baxter** » 04 May 2008, 22:32

http://www.youtube.com/watch?v=m6fYi13C ... re=related

Seems that this is the A6 lump.

Post by **Pat Dolan** » 05 May 2008, 17:24

Simon:

Thanks for the replies (and the links you sent me). Sorry to take so long to respond, but I am (as usual) travelling and get bent over the cost of connections at airports.

I will check in at the other forum(s...forae), but I am here because it is going in as an alternate engine for a T3 Syccro. I am delighted to learn that the K14 will put enough air through that tiny compressor for a bit more power (cold side must be different much over 100, not so).

Regards - Pat