AAZ 1.9TD into bay thats sporting a 1.6D?

[Bugsy_malone 666]

ok, got the chance to do an engine upgrade!

up until a couple of weeks ago my bay was a 1.6 non turbo diesel T25 engine/bell housing. the engine broke down (no idea why yet, i just put it back to petrol quickly to get me to vanfest) othing serious, just something like a fuel solinoid i think.

so I have the chance to buy a 1.9 AAZ TD engine at a reasonable price and I was wondering how easy it is to 'bolt in'

obviously I have the engine mounts and all the bits relating to it being diesel.

turbo oil drain, is this an issue or do i need to do any mods? (stock golf drains oil to half way down the block, surely this would still work?)

is there any clearance issues with the Turbo/inlet?

id rather just fix the 1.6 and put that back in if there will be tons of work, but obviously if its just a case of getting the AAZ, sticking a new T25 oil pump on, oil sump and engine mounts and then off I go then i`d like to upgrade.
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Second Gear All The Way Baby!

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[richbaker78]

i did the same to a t25 recently...and found this very useful - think it answeers all your questions.

http://www.brick-yard.co.uk/VehicleSpecific/T3/info/mods/aaz.htm

if you need a JX sump I have one for sale - can take to vanfest.

If doing again I would use the AAZ manifolds etc and cut and shut them as required - esp the exhaust. I would also try and re-use the AAZ turbo/ inlet manifold as its better and re-index the turbo. but im sure you can weigh up the pros and cons - and i think 13window is a lot more knowledgable on this.

I still have some bits of JX left but cant rememebr what - plus 13 window is already having the manifolds of me i think.

[Bugsy_malone 666]

what price would you want for the sump?


reading that guide I am thinking it might not be worth bothering to be honest!

so far my diesel engine conversion has yet to pay for its self, once it does then an upgrade might be an idea.

however theres also the idea that should the engine and required parts be cheap enough then it outweighs trying to fix my other engine.
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Second Gear All The Way Baby!

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[richbaker78]

£30 for the sump.

the conversion i did was for a van i sold - and frankly I thought the power delivery was pretty sh*t even though everyone raved about it on those t25 forums as the 'best' option. i guess im used to driving a more powerful deisel (merc vito) by day but even so its a 75 bhp engine at the end of the day which is pretty rubbish for a 1.9 Turbo! although they cna be tuned up over 100 (apparently) i think if i were doing it again i would save my £ and effort and direct it towards fitting a later type VW diesel. Much more refined, more power, more expensive and more complicated...but not impossible and ultimatly a better end result.

Just my opinion after my brief and dissapointing encounter with AAZ engines...

[Bugsy_malone 666]

Yeah I did think you`d want alot more than that for the sump, I have turned the offer of the engine down.

it would be £150, plus im not sure about the oil pump on my 1.6 so I'd need to buy a new one so thats another 50 quid, then your sump at 30 then I'd need to build an exhaust system.

my current setup hasnt paid for itself yet, and i thought if i want more power a supercharger might fit the bill as it perminantly runs I can just up the basic fueling on the pump should do it, unless I got hold of a turbo pump (not sure what the difference is, something to do with fuel control?)

and for the 200+ quid it would cost to go bigger, I could go supercharged and have that fun whining sound
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[richbaker78]

not a bad price for an AAZ. but i think its a good choice as it will be cheaper to fix the old lump I guess. whats up with the 1.6D ?

i dont think your idea with the supercharger as you describe will work tbh you would really need to run the TD pump I would have thought as it has an enrichment system built in. although the supercharger runs all the time it doesnt mean it provides permanent boost. Boost will still be greater at greater speeds so simply enriching the fuelling wont give you the additional fuelling across the range - doing as you describe will lean it out the further you get from idle.

The TD pump is a simple systme which has like a second throttle system operated by a diapragm which you link to your boosted inlet....so it effectively opens the additional throttle and provides more fuel under boost.

have you investigated the CR of the standard D engine? you may find its too high to just bolt on the supercharger. supercharging is not gona get you much more than Turboing really - so given the choice between a TD which you can get off the shelf and creating your own supercharged engine i think you would save a lot of grief going with something the VW already designed for you.

As i sadi above i would condier a later Tdi engine if i were you once the existing engine is up and running again.

dont get me wrong im all for supercharging - but really on a 60 bhp base engine it could be expensive gains per HP and a lot of effort.

just my opinion im sure others will have something to say. 13 windows your man on the TD/TDi stuff anyway.

[Bugsy_malone 666]

Yeah I know what your saying, with the current 1600D firstly I need to replace the oil pump, secondly I need to find out why it just wouldnt start after I switched it off at tescos one day, it drove there without hic-up!

I love the idea of supercharging and I know what your saying about compression ratios etc, I have had a look at my haynes manual for my mk3 golf that has the 1.9 in and strangely enough it seems turbo or not the CR remains about the same. The alternative is that I get a TD pump at some point.

I just think againt messing about with a sump, getting a turbo that might not be so grand I could fit something like the eaton of the new mini designed for a 1.6 engine (not that it makes much difference) and engineer something, most importantly doing something different!

the supercharging idea is an over time thing.

I`ll keep my eyes peeled for a 1Z TDi thats 90bhp, I know you can get them upto about 230bhp with enough work ( so I have heard) but I might try making a custom adaptor plate to fit other lumps.

the cost of the quick fix is a bit expencive till the conversions paid for itself.

then theres the whole running it on chip oil thing, better to start testing on an old engine!
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Second Gear All The Way Baby!

Doing Thing Differently.

[richbaker78]

for a sudden stop like that it must be a fuel supply issue...fuel cut off valve stuck?

You will need a TD pump as a minimum i would think, and poss bigger injectors. PPC mag did a good series of articles on supercharging a few month ago might be worth getting a back issue.

[13 window deluxe]

to be honest i think the supercharger idea is a bad one, why mess about building a custom forced setup when you can have a stock turbo diesel setup? the aaz is easy to fit in a already diesel van the only bits to swap would be a turbo diesel sump with oil drain fitted, you can use the larger aaz oil pump with the oil pick up pipe off you current oil t25 pump the aaz turbo can be used with the left t25 engine mount if the turbo actuator is moved that just leaves the turbo oil drain which is moved from the high up location on the block and blocked up with a hydraulic pipe cap and a new line made up using hydraulic oil fittings did this on my 1z tdi t25 cost less than £20 for all fittings oil hose and block bung , the standard aaz engine is pants in a t25 there just to heavy thats why i had the 1z in mine but a aaz is worlds apart from the old 1.6d 75bhp instead of 50bhp and 107ft/lbs instead of 55ft/lbs and would pull a bay a treat with the 1.6 lawn mower box you will be smoking all the local boy racers from the lights with the aaz in my split and the upgeared 03 box (making for slower acceloration) i can smoke my mate in his brand new 100bhp transit up to 60mph !!!!! all in all the aaz swap would be worth while in a bay i would go for it, the 1z in you bay is a whole different kettle of fish with the wiring and immobiliser etc dont be tempted to do away with it and use the aaz pump on a 1z its just not tennis
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[Bugsy_malone 666]

grrrr i want one now lol

richie, i think I might take you up on the deal with you sump!

least then if the AAZ is still available when payday comes I can buy that!
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Second Gear All The Way Baby!

Doing Thing Differently.

[richbaker78]

no probs - see you at VF

[Dubwin]

You can tune an AAZ to make just as much power as a 1Z, only you don't need to bother swapping pumps around.
You can machine the crank nose to accept the TDI pulley, and that weakness is solved. Or if it's still in perfect nick, just buy a new bolt and torque it up to the correct spec (140lbs iirc?) and fit a clutched alternator.
Most AAZ's are run on setups that use non-clutched alternators, and therefore on sudden throttle lift the alternator actually (albeit briefly) puts stress in the reverse direction of the crank pulley.

With the right turbo, boost pin, intercooler and fueling you can pretty easily reach 200bhp. Some AAZ's came with a turbo big enough to do this, some didn't. The AAZ boost pin is crap, a lot of people swap them out for GTD pins or rover / peugeot items - or you can grind the AAZ boost pin which will offer much more aggressive fueling on boost.
After 200bhp I'd be looking to replace the head bolts with ARP head studs and steel head gaskets 'cause sooner or later (sooner, rather than later) with that amount of power they're going to give.
Then you can happily keep on upping fuel and boost until your engine internals start to melt
Then you're into a whole 'nother league which costs buck$$$$.

The AAZ pump is pretty underpowered compared to the stock TDI pump in terms of maximum capability.
If you're going to use a mechanical pump on a 1Z engine it's better to look for a pump with a 10mm+ head and plunger and larger camplate. These items can be swapped over into the AAZ pump from the 1Z pump, but it's fiddly and if you're looking for a donor pump anyway, may as well get one that already has them. Bosch pumps in Peugeots and mk2 escorts sometimes have them.