AAZ on the way and I have ?'s

[jack's lack]

hey Gurus

I have finally sourced an AAZ (with pump and turbo), and it looks like it will be making its way down to the dirty south next week 
The 1.6 NA is running reasonably fine and I would like to take the time to mod/repair the new lump before I drop it in the Rabbit.
I'm not looking to make huge numbers. I would like it to rev high and quick (as can be expected for a diesel), not be too laggy, and I would like to maintain the maximum fuel economy.
It would be great if it would blow the doors of my little sister's MKIV Jetta (1.8T gasser)

I have read the make your_ a faster car threads and they seem to focus mostly on the pump
I will def send the pump off to Giles, what he did to my NA pump was magical. I will also do a larger downpipe and new exhaust.

I don't know a lot about what is available for these engines as far as performance upgrades, so I turn to you for advice
If you had lets say $5,000 USD max to throw at an AAZ what would you do?

Thanks so much for all your advice on this and everything in the past,
Cheers,
Ryan

[burn_your_money]

Well you are off to a good start with the larger exhaust, downpipe and pump.

What turbo does your AAZ have?

P&P the head would be good if you are planning on taking it off. Since you are getting a new exhaust and downpipe you might want to look into using a better intake manifold.

Probably first on the list would be having the crank gear machined to the D shaped TDI style one so you don't blow your baby up

[GEE-BEE]

Techtonic's on the downpipe 2.5' and exhaust system...

They did S/S for me on both...

Contact Josh at Techtonics.com


Next do some guages from McNallyelectronics.com

Gee-Bee

[stopping]

In the 5G budget for me in order of priority would be:

-Crank milling to D pulley (TDI)... easier and a better job if you pull the crank.
-This would lead me to new over-sized pistons, bearings (rod bushings too)... performance rods?
-EGT sensor/guage
-a good intercooler and set up
-boost guage
-boost pressure cut off in the cab: eco mode for economy on the highway then with a switch or valve.... as have a richer mix for full fuel turbo time!
-this is kind of fun... I might never do most of this stuff cause I will never have the money....... some day!

I think of it as a challenge.... those 1.8T's are fast!

[molgrips]

But properly tuning the LDA isn't that easy is it?  Unless you can get custom wound springs for it...

[jack's lack]

I'm into the idea of having the head P&P'd, but I don't want to do a DIY hackjob. Is there someone you can recommend? would larger valves be in order? I have seen these Mexican made Kolbenschmidt (sp?) heads floating around on ebay, are they worth the $$$?

I don't know what turbo is on the AAZ (total noob move not to ask huh?) I assumed It was a KKK (unfortunate brand name to have in my part of the world) K-14. Dude said in the sale ad that it would not fit in his vanagon because it was a golf turbo, does this tell us anything? Obviously this question will be answered when it gets here. I see a lot of people going to larger Garrets and VNT's would one of these be better for my goals?

The Techtonics exhaust is sick, as soon as I figure out what turbo I have/am going with I will have him make something up. I noticed he didn't have a 2.5 downpipe as an option, is that something you had to have him custom fab?

Boost EGT and an Intercooler are at the top of my list. I was thinking oil temp too and I have the little air to oil cooler out of a Volvo i grabbed at the boneyard I thought it might be a good idea.

I noticed everyone has said to mill the crank for the D pulley. Is this the notorious crank keyway issue I have been reading about? Could any machine shop do this, cause no one works on VW around here I had to go to 5 places just to get my motor mounts pressed in. I guess if I am pulling the crank I might as well rebuild the damn thing

performance rods huh, do people make forged internals for these things? Billet goodies might take this thing out of my price range real fast though, so as long as I am not at a risk of throwing a rod I might have to forgo those bits

I'm with Andrew on the fueling and boost control. I have always imagined this project as analog and mechanical. there is something very seductive about visible simplicity and logic that is lost as soon as one introduces circuit boards and digital displays, not to mention my bunny's track record with thing electronic is tainted at best. That being said McNally is out I prefer the simple aircraft look of the VDO, Is there a more accurate choice that doesn't look like it came out of a spacecraft?

Yes the 1.8T is fast, but I am 1000#'s lighter
anyway thanks for the advice so far. I am starting to get a sense of where I am going to go with this thing. I guess I owe you a build thread now.

[vanbcguy]

-boost pressure cut off in the cab: eco mode for economy on the highway then with a switch or valve.... as have a richer mix for full fuel turbo time!

Despite anything hagar says on the dieselparts forum, ECO mode is not more efficient or more economical than having a properly tuned LDA, in fact it is worse.

I don't think you get what hagar is doing... He's purposely reducing the power output of his engine under normal driving conditions to get better mileage, but still has the ability to engage the LDA on demand should he feel like having full power.  The idea is to still properly tune the LDA and max fuel screw for best performance, but then have the ability to engage/disengage the LDA at will.

Disconnecting the LDA doesn't make the engine use more fuel...

[theman53]

If you talk to *John* I think is his name at
Air Cooled Engines Plus, local profile:

Address: 286 2nd Avenue
City: Tiffin
State: Ohio
 
ZIP: 44883
Phone: (419)443-8987

For 5 minutes you will know that this guy not only knows his stuff, but lives it. I would take anything and everything to this guy. I think boosted bunny 84 or something close to that username has used him as well. Very professional and even more knowledgable. Definately NOT a hack. If you want a P&P job or valves or whatever he will recommend exactly what you need.

[GEE-BEE]

Speak with Josh at Techtonic's , they will make you a 2.5 DP no problem....

Dealer price 375.00

Iam doing a 2.5 exhaust also with a magaflow muffler

[jack's lack]

I spoke to Joey at techtonics, I assume he works with Josh, and as soon as I get the engine and figure out which turbo (outlet) is on it we are going to go ahead and get started. That does beg the question of whether or not to change to a different turbo before I drop a $K on a custom made SS exhaust.

I ordered the aircraftspruce thermocouple and Isspro EGT gauge, I also grabbed a boost gauge and an oil temp gauge as well. I'm going to mount them in the din under the stereo where the AC vents would be if I were afforded that luxury.

I ordered the TDI alternator pulley with the freewheel design, which was easy to find, but I have been searching and have found several part #'s for the crank pulley and all the links on the thread with the pics are dead

Do I need the gear that drives the timing belt, the pulley for the serp belt the harmonic balancer or all of the above?

Also I read that I can use a 1Z or AHU code TDI crankshaft and avoid the machining since crank removal is almost necessary this seems the more logical option

[stopping]

If you change the crank you will likely need to change the bearings... maybe not.

So you know. Machining the crank for the new pulley only cost me 35$...plus the cost of a new TDI pulley. (But you would need to have a crank in good shape to start with.) It can be done by a competent machinist... maybe not an engine specific shop.... there is a shop here where they machine anything.... and thoughtfully.

If you have it out you might want to Plastiguage it anyhow, just to see where it's at in terms of wear. (I mean main and rod bearings.)


(bcvanguy... I don't know what your talking about or who your talking to)

Andrew... I will read that thread.... not sure I have yet, thanks.

[Syncroincity]

I'm the one supplying this motor... I don't know the model of the turbo, but it's the one with an integral wastegate actuator that sort of looks like a model airplane engine, w/ cooling fins. The exhaust, what I could see, looks to be trapezoidal turbo inlet, and square flange/round hole outlet, with a blocking plate between the turbo & exhaust flange. I can break open the crate before I ship it to look at it closer, if you need better info. That weird wastegate was the reason it wouldn't work with a T3; motor mount interference.

[Syncroincity]

Heads-up... make sure you check the condition of your oil cooler... mine was half crushed at the back from the motor being rested on the oil filter.

[Vincent Waldon]

trapezoidal turbo inlet

K14... score !!!   

[GEE-BEE]

TECHTONIC'S now has both models to make a DP from k03/k24 & k14

Please let them know Gee-Bee sent you , they did alot of in the last eight month's


Gee-Bee

Iam currently working on the bump stop's for the caddy