Alternative engine 1.9TD - Revision history

HarryMann at 12:59, 3 November 2025

2025-11-03T12:59:37Z

← Older revision		Revision as of 12:59, 3 November 2025
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	[[Image:AAZ_DipstickMod_01_new.JPG]] [[Image:AAZ_DipstickMod_02_new.JPG]]		[[Image:AAZ_DipstickMod_01_new.JPG]] [[Image:AAZ_DipstickMod_02_new.JPG]]

	[[Image:~~AAZ_DipstickMod_03~~.JPG]]		[[Image:AAZ_DipstickMod_03_new.JPG]]

	Correct oil level is then about minimum on stick, but calibrate it anyway, with 4.5 litres + allowance for oil cooler if fitted (another 0.5 ~ 0.75 litres depending on cooler size and pipe run)		Correct oil level is then about minimum on stick, but calibrate it anyway, with 4.5 litres + allowance for oil cooler if fitted (another 0.5 ~ 0.75 litres depending on cooler size and pipe run)

HarryMann at 12:58, 3 November 2025

2025-11-03T12:58:12Z

← Older revision		Revision as of 12:58, 3 November 2025
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	'''HarryMann:''' Also note that with some diesel dipsticks the correct oil level won't even be on the bottom of the stick, so shortening the dipstick ''tube'' is the normal remedy (for the AAZ anyway). About an inch and a quarter reduction from memory, or where there's a natural change in section, so that the yellow plastic scroll-clip can be re-fitted, finishing it all nicely.		'''HarryMann:''' Also note that with some diesel dipsticks the correct oil level won't even be on the bottom of the stick, so shortening the dipstick ''tube'' is the normal remedy (for the AAZ anyway). About an inch and a quarter reduction from memory, or where there's a natural change in section, so that the yellow plastic scroll-clip can be re-fitted, finishing it all nicely.

	[[Image:AAZ_DipstickMod_01_new.JPG]] [[Image:~~AAZ_DipstickMod_02~~.JPG]]		[[Image:AAZ_DipstickMod_01_new.JPG]] [[Image:AAZ_DipstickMod_02_new.JPG]]

	[[Image:AAZ_DipstickMod_03.JPG]]		[[Image:AAZ_DipstickMod_03.JPG]]

HarryMann at 12:57, 3 November 2025

2025-11-03T12:57:14Z

← Older revision		Revision as of 12:57, 3 November 2025
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	'''HarryMann:''' Also note that with some diesel dipsticks the correct oil level won't even be on the bottom of the stick, so shortening the dipstick ''tube'' is the normal remedy (for the AAZ anyway). About an inch and a quarter reduction from memory, or where there's a natural change in section, so that the yellow plastic scroll-clip can be re-fitted, finishing it all nicely.		'''HarryMann:''' Also note that with some diesel dipsticks the correct oil level won't even be on the bottom of the stick, so shortening the dipstick ''tube'' is the normal remedy (for the AAZ anyway). About an inch and a quarter reduction from memory, or where there's a natural change in section, so that the yellow plastic scroll-clip can be re-fitted, finishing it all nicely.

	[[Image:~~AAZ_DipstickMod_01~~.JPG]] [[Image:AAZ_DipstickMod_02.JPG]]		[[Image:AAZ_DipstickMod_01_new.JPG]] [[Image:AAZ_DipstickMod_02.JPG]]

	[[Image:AAZ_DipstickMod_03.JPG]]		[[Image:AAZ_DipstickMod_03.JPG]]

HarryMann: /* Other considerations */

2010-08-07T01:52:32Z

Other considerations

← Older revision		Revision as of 01:52, 7 August 2010
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	There are various upgrades but usually require re-machined flywheel from a different vehicle		There are various upgrades but usually require re-machined flywheel from a different vehicle

	[[Diesel Uprated Clutch]]		[[Gearbox Clutch CVs - Diesel Uprated Clutch]]

	[[Diesel clutch ~~installation considerations~~]]		[[Gearbox Clutch CVs - Diesel clutch change]]

	== Turbos ==		== Turbos ==

HarryMann: /* Other considerations */

2010-08-07T01:50:37Z

Other considerations

← Older revision		Revision as of 01:50, 7 August 2010
Line 97:		Line 97:

	There are various upgrades but usually require re-machined flywheel from a different vehicle		There are various upgrades but usually require re-machined flywheel from a different vehicle

			[[Diesel Uprated Clutch]]

			[[Diesel clutch installation considerations]]

	== Turbos ==		== Turbos ==

HarryMann: /* Other considerations */

2010-08-07T01:34:11Z

Other considerations

← Older revision		Revision as of 01:34, 7 August 2010
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	== Other considerations ==		== Other considerations ==

			Clutch... Some find the std JX 215mm clutch usually slips with a good AAZ, others find it doesn't

			There are various upgrades but usually require re-machined flywheel from a different vehicle

	== Turbos ==		== Turbos ==

HarryMann: /* Inlet Manifold */

2008-09-23T10:26:25Z

Inlet Manifold

← Older revision		Revision as of 10:26, 23 September 2008
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	[[Image:JX_InletMan-ModForAAZ_01.jpg]]		[[Image:JX_InletMan-ModForAAZ_01.jpg]]

	Using the AAZ manifold is probably the best option, but this has the inlet stub on the top, not the outside face. A different inlet hose and general arrangement is then needed. In theory it would be possible to adapt the AAZ manifold to have a side mounted inlet stub, as the casting is nominally the same.		Using the AAZ manifold is probably the best option, but this has the inlet stub on the top, not the outside face. A different inlet hose and general arrangement is then needed.

			If you are going to intercool then this (original AAZ)is probably the best inlet manifold to use, with the stub turned towards the rear for clearance, using a variety of silicon hoses and joins. Note well the correct stub port diameter, which has a habit of falling between common hose sizes. So at least acquire/keep the original AAZ inlet hose, to use or as a guide.

			In theory it would be possible to adapt the AAZ manifold to have a side mounted inlet stub, as the casting is nominally the same.

	== Exhaust Manifold/Pipe/Silencer==		== Exhaust Manifold/Pipe/Silencer==

HarryMann: /* Donors and Parts Required */

2007-07-10T23:07:52Z

Donors and Parts Required

← Older revision		Revision as of 23:07, 10 July 2007
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	== Donors and Parts Required ==		== Donors and Parts Required ==

	Try looking at this link for some info given to me by and by me as I did my AAZ conversion earlier this year.		'''GaryD:''' Try looking at this link for some info given to me by and by me as I did my AAZ conversion earlier this year.

	http://forum.80-90.co.uk/viewtopic.php?t=17057&postdays=0&postorder=asc&highlight=aaz&start=0		http://forum.80-90.co.uk/viewtopic.php?t=17057&postdays=0&postorder=asc&highlight=aaz&start=0
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	Prices in brackets are VW with aftermarket prices following.		Prices in brackets are VW with aftermarket prices following.

	Hope this helps		Hope this helps

	Garyd		Garyd

	Exhaust manifold ~~and turbo mating faces~~

			'''HarryMann:''' Exhaust manifold parts

	The manifold studs, nuts and extra thick washers are quite importannt to be in good nick and done up well. Being a TD, manifold moves about a lot as it gets ''very'' hot, so should have good flat mating faces to the head and new gaskets. They can be trouble free for quite along time if everything is right...		The manifold studs, nuts and extra thick washers are quite importannt to be in good nick and done up well. Being a TD, manifold moves about a lot as it gets ''very'' hot, so should have good flat mating faces to the head and new gaskets. They can be trouble free for quite along time if everything is right...

HarryMann: /* Donors and Parts Required */

2007-07-10T23:04:25Z

Donors and Parts Required

HarryMann: /* Engine Options */

2007-07-10T23:04:18Z

Engine Options

← Older revision		Revision as of 23:04, 10 July 2007
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	== Engine Options ==		== Engine Options ==

	Donors and Parts Required ==		== Donors and Parts Required ==

	Try looking at this link for some info given to me by and by me as I did my AAZ conversion earlier this year.		Try looking at this link for some info given to me by and by me as I did my AAZ conversion earlier this year.

← Older revision		Revision as of 23:04, 10 July 2007
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	Fit new JX parts: Number Price		Fit new JX parts: Number Price

	clutch assembly 068 298 141 DX (110) £63.50		clutch assembly 068 298 141 DX (110) £63.50

	Crankshaft spigot bearing 111 105 313 A £5.50		Crankshaft spigot bearing 111 105 313 A £5.50

	Sump gasket 044 103 609 D (18.56) £7.01		Sump gasket 044 103 609 D (18.56) £7.01

	Oil filler pipe gasket 068 115 315 A £1.22		Oil filler pipe gasket 068 115 315 A £1.22

	Sump drain plug seal washer N013 849 2		Sump drain plug seal washer N013 849 2

	Alternator / water pump belt		Alternator / water pump belt

	Water housing ‘O’ ring 2no. 052 121 091 A £1.00		Water housing ‘O’ ring 2no. 052 121 091 A £1.00

	Exhaust gasket (turbo to pipe) 893 253 115 £3.73		Exhaust gasket (turbo to pipe) 893 253 115 £3.73

	Exhaust manifold to head gaskets. 4no 028 129 589 B £2.25 each		Exhaust manifold to head gaskets. 4no 028 129 589 B £2.25 each

	Heat shields – 2 parts 068 253 283 & 068 253 283 A £13.76 each		Heat shields – 2 parts 068 253 283 & 068 253 283 A £13.76 each

	Fit new AAZ parts (engine no – AAZ 504 742):		Fit new AAZ parts (engine no – AAZ 504 742):

	Timing belt & adjuster 028 109 119 P & 068 109 2430F £20.00 & £30.76		Timing belt & adjuster 028 109 119 P & 068 109 2430F £20.00 & £30.76

	Oil cooler ‘O’ ring seal 028 117 070 £3.77		Oil cooler ‘O’ ring seal 028 117 070 £3.77

	Oil Filter 068 115 561 B £6.59		Oil Filter 068 115 561 B £6.59

	Crankshaft oil seals (Fr 068 103 085 E) & (R 068 103 171 F) £4.17 & £8.45		Crankshaft oil seals (Fr 068 103 085 E) & (R 068 103 171 F) £4.17 & £8.45

	Crankshaft oil seal gaskets Fr 026 103 161 B & R 026 103 181 B £1.46 each		Crankshaft oil seal gaskets Fr 026 103 161 B & R 026 103 181 B £1.46 each

	Crankshaft pulley end bolt (M14 x 1.5 x 47) N905 771 01 £1.37		Crankshaft pulley end bolt (M14 x 1.5 x 47) N905 771 01 £1.37

	Flywheel bolts 6no N902 061 03 £1.84 each		Flywheel bolts 6no N902 061 03 £1.84 each

	Inlet manifold gasket 028 129 717 D £4.19		Inlet manifold gasket 028 129 717 D £4.19

	Inlet manifold elbow gasket 028 129 754 A £3.25		Inlet manifold elbow gasket 028 129 754 A £3.25

	Water hose – pump to cylinder head (AAZ) 028 121 053 Q (19.85)		Water hose – pump to cylinder head (AAZ) 028 121 053 Q (19.85)

	Coolant Thermostat ‘O’ ring seal 038 121 119 B £1.48		Coolant Thermostat ‘O’ ring seal 038 121 119 B £1.48

	Timing belt cover 028 109 123 E £15.97		Timing belt cover 028 109 123 E £15.97