KKK exhaust gasket and Parts in General for 1.9TD AAZ? - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• KKK exhaust gasket and Parts in General for 1.9TD AAZ? by dosma on 22 Jun, 2005 08:14
• Hello All,
  
  I'm new to the list. I posted to the list a couple of months ago before delivery of my Westy with new 1.9 AAZ.  I have it now and am very happy with its performance.
  
  Now I need to find souces for parts for the engine.  I'm in the U.S. where the engine is not  stamdard in a vehicle.
  
  Of immediate need is an exhaust output gasket for the turbo.  I believe it's a KKK.  The engine has 2k miles on it now and I just discovered that  it has a broken off stud in the turbo exhaust output flange.  In addition exhaust hardware was not used to bolt the custom exhaust pipe on and the nuts vibrated loose.  I will be removing the turbo to remove the broken off stud. Of course the exhaust gasket  has blown through.  What other gaskets may I need to reinstall the turbo?  Does the turbo to intake manafold require a gasket?
  
  Any ideas for sourcing this gasket as well as other parts relating to a late model 1.9TD AAZ would be helpful.
  
  Thanks in advance for your help.
• #1 by fspGTD on 22 Jun, 2005 10:07
• The 1.9lTD AAZ engine was sold in canada, and you might find that a US VW dealership can get these parts, as the parts database at least is common for all north american applications.  If all else fails you could mail order from a candian source, or from us-based World impex, which can get seemingly any north american VW Dealer part the dealer can get but at a discount: www.worldimpex.com
  
  I am showing for the tubine outlet gasket, VW part numbers 893 253 115 (for engine number up to 1H-R-045 250) and part numbers 1H0 253 115 A (for engine number 1H-R-045 251 and beyond).  I'm guessing there are two different turbos that cames on the AAZ so you'll need to figure out if you have the earlier or the later one...
  
  A replacement turbine outlet stud, 902 934 01, is listed only for engine up to 1H-R-045 250.  It is 8mx43mm.
  
  Nuts to hold downpipe to turbine outlet are N 902 002 01
  
  There is no turbine inlet gasket.
  
  There also from the parts database for Jetta AAZ application, what looks like a bracket that braces the downpipe to the exhaust manifold.  Having  brace like that in your installation would make life easier on your turbine outlet fasteners.  You should also have a nice flex-joint in your exhaust, the closer to the turbine outlet, the better.
  
  Since it sounds like this may be the first time removing the turbo... I would recommend using copper-based anti-seize on the turbo mounting bolts when re-installing it.  Competing grey antiseizes can't take the heat and dry/crumble.  Not a bad idea to use the copper anti-seize on any other exhaust fasteners that also might get pretty hot as well.
• #2 by dosma on 22 Jun, 2005 12:07
• Hello Jake,
  
  Thanks for the very complete response.  I'll have to look into getting a parts list myself somewhere.  Any ideas here?
  
  Since this engine is reportedly just over from Germany, I'll assume it's the later version.  Elsewhere I saw it reported that this engine has a KKK turbo.  I'll use your part numbers as a start.
  
  By the way, I'm looking at my exhaust setup and I have concerns. I'm completely new to Vanagons so am just learning the system and  seeing things I didn't see before.  The exhaust system is completely custom.  The muffler is welded to a 6 in. flex tube which is welded to a pipe section terminating at a flange that is bolted to the turbo.  The pipe diameter is 2 1/4 and has a free flow muffler.  the muffler is supported on either side with flexible straps that are bolted to the chasis back lower sheetmetal.  I'm concerned that as the engine mounts flex, that the exhaust flex tube is not enough to compensate and that a lot of force will be applied to the turbo flange.  There is no support bracket to the engine.  I could probably get a bracket fabricated.  The other alternative is to obtain the muffler attachment brackets from my old 1.6na engine and mount the muffler to the engine like the factory does.    What do you think?
  
  ...Don
• #3 by Baxter on 23 Jun, 2005 15:52
• 
  
  Thats a quick screen cap from European ETKA, the exhaust in question is from a "JX" 1.6TD.
  When carrying out AAZ conversions the stock "JX" exhaust can be used with only a slight adjustment to the clamp to the rear silencer due to the extra 19mm of height of the 1.9 engine as oppsed to the 1.6l.
  
  I sell that system at £165 fitted, thats about $350 - ish I think.
  
  You would need..
  Gasket, as mentioned.
  Down pipe.
  Silencer.
  3 rubber mounts.
  mounting bars.
  tailpipe.
  tailpipe gasket.
• #4 by dosma on 24 Jun, 2005 12:07
• Thanks for the exploded view of the 1.6TD Vanagon set up.  Do you ship to the U.S.?  If so, what would you charge and any idea of what shipping to California might cost?  I've contacted the folks that did my conversion and asked them to send me all brackets assoiated with the muffler that came off my Westy engine.  I'm also getting the under carriage heat shields and bolt up sheet metal as well.  My present plan is to use what I can of the stock 1.6L NA engine parts to install the free flow exhaust to the engine.
  
  The diagram helps me to visualize what I need.
• #5 by Baxter on 25 Jun, 2005 08:36
• I have not looked into the possibility of shipping to the US.
  I can look into it if you require?
  How much bracketry do you already have?
  I would leave the *** shields off to be honest, they are a right pain to fit and remove, the only detrement I can see is that the turbo bolts are exposed and they get quite rusty very quickly.
  I would spend my time making a shield for this rather than messing around with those under shields.
  the 1.6NA exhaust is very puny indeed compared to the butch 1.6TD system, I would be surprised if any of it was of any use to you.
  The brackets that hold the exhaust are bolted to the left hand engine mounting, and the sump at the right hand side, if you can get those then you have cracked it, all that is needed is the exhaust sections.
• #6 by dosma on 27 Jun, 2005 08:57
• Mr. B, no need to send info about shipping from the UK at this time but thanks. My plan as it stands is that I will use what I have in addition to brackets from my 1.6NA to mount my muffler to the engine.
  
  What came with the car from the folks doing the conversion was a completely fabricated and welded muffler from the turbo exhaust flange to the muffler tip.  I'm not sure what I will get for mounting from the shop that did the work.  I'm expecting to receive both engine brackets, item 13 and the left motor bracket in your diagram.  If I get the rubber mounts, I may forgo a flex joint in the downtube.  Otherwise, I plan to mount the muffler rigidly to the motor by welding brackets to the muffler/tailpipe that I can bolt to the engine brackets and then insert a flex tube into the turbo downtube.  Anyone see a problem with either of these two arrangements?  For example, does the engine need to be isolated from the muffler by flexible rubber mounts for vibration reasons between the two, auditory or otherwise, or are the rubber mounts primarily to give flex between the muffler and turbo?
  
  This is new to me on Vanagons but hopefully I can come up with a working solution the first attempt.
  
  Thanks for your comments.
• #7 by Baxter on 27 Jun, 2005 15:57
• Tailpipe - http://217.29.195.146/FMPro?-db=wproducts.fp5&-format=detail.htm&-lay=cgi&-sortfield=name&-sortorder=descend&Category=Exhaust-heatexchanger-parts&Find%5fWeb=T3&-max=10&-recid=39&-token.0=13203778&-find=
  
  Downpipe. - http://217.29.195.146/FMPro?-db=wproducts.fp5&-format=detail.htm&-lay=cgi&-sortfield=name&-sortorder=descend&Category=Exhaust-heatexchanger-parts&Find%5fWeb=T3&-max=10&-recid=39&-token.0=13203778&-find=
  
  Silencer - http://217.29.195.146/FMPro?-db=wproducts.fp5&-format=detail.htm&-lay=cgi&-sortfield=name&-sortorder=descend&Category=Exhaust-heatexchanger-parts&Find%5fWeb=T3&-max=10&-recid=10&-token.0=13203778&-find=
  
  Probably best to order from http://www.justkampers.co.uk Similar prices and they are set up for international order, when your ready that is.
  
  Also, maybe worth a read of my webiste http://www.brick-yard.co.uk