Most cost effective way of installing AAZ in 82 Vanagon diesel

[ilikevwdiesel]

Thinking about picking up an 82 Vanagon diesel and upgrading it to an AAZ and 5 speed trans. I know the factory TD Vanagons used the same turbo and manifolds as a Quantum, does anyone know if there are any AAZ setups that will just bolt in without having to do a bunch of cutting and welding on the mounts, etc? I can handle getting an exhaust done but I'd rather not get into a bunch of fab work as I don't weld.  If you've installed an AAZ into a factory Vanagon diesel I'd love to hear your Monday morning quarterback commentary.

[bridgetroll13]

I am running that exact combination. I bought an AAZ from VW motors in Montclair CA. I was lucky in that it came set up to go into a Vanagon already so I didn't need to create the drivers side mount. It also came with the later style engine mounting bars which move the motor back in order to accommodate the longer 5 speed.

I purchased an AAP 5 speed from a guy in Canada which has a low numerical final drive (not the stock diesel 5 speed). The front section of the linkage is unique; first is below reverse (I have heard of people modifying 4 speed linkages to work). The rear section is the same as the later style 4 speed. Also take note that the entire linkage is different that the early style so you will need the bushing that mounts on the bulkhead just behind the gas tank. The bushing in the original location above the tank is too tight for the later linkage rod and the location makes the geometry screwy.

I am mostly pleased with the combination as it will comfortably cruise at 65 mph without feeling like it's going to rev itself to death but I don't have to fry the clutch to take off from a dead stop. The gear change from 1st to 2nd is not quick though so I still tend to have people running up on me when taking off from a dead stop.

Both the engine and transmission were nearly worn out when I got them and had to be rebuilt which was painful as neither were cheap in the first place. The bores in the motor were worn (oval) enough to require being bored out and over-sized pistons installed. The transmission suffered the infamous 3-4 slider failure (except in this case it's 4-5) and required replacing not only the slider but also a gear-set that had been chipped at some point in its life.

If I'd had all the money that I ended up sinking into it up front I probably could have found something pretty nice to buy without having to do all that work. On the other hand I am a glutton for punishment and inclined to own funky old stuff which wants perpetual tinkering.

Erik

'82 diesel Vanagon
'89 diesel Jetta

[ilikevwdiesel]

I've seen 3 bad motors from that guy...Thomas in Montclair. I am hip to installing the 5 speed that part I have done before,what I am most interested in is what is the best stock turbo and how everything works out. Andrew gave me a good start, what did you do to your turbo and oil lines?

[bridgetroll13]

Yes, I am afraid his stuff is mostly very well used.

The motor that I bought from him had already been set up for life in a Vanagon. It came with a K14 which appeared to have been what came with the motor in its original vehicle. The turbo drain is a banjo fitting at the block which apparently is not the ultimate set-up (but stock). The mounting flange for the exhaust manifold is the trapezoidal shape that I believe also fits a TO3.

[wildenbeast]

I also bought an AAZ engine from Thomas in Montclair.  The original block had a hairline crack in it.  I was able to negotiate a trade for a brand new long block that he had though so I was quite pleased with his customer service after what initially appeared to be a major setback (I wish I could say the same for prothe's injection pump and turbo...). 

Back to your question; I am using a T2 turbo (it is a stock turbo) which is similar in size and performance to the K14.  It will boost up to 20psi quite easily but I currently have it set at 17psi.  I have had no problems with it in the year I have been using it.  I once blew off the silicone connection to the turbo but since then have found better t-bolt clamps that don't need constant tightening. 

I have photos of how my oil lines were run on the original block here; http://billwildenberg.shutterfly.com/vwvanagon
However, the new german block had a different routing for the turbo drain.  I can take more photos if you're interested.

Bill