Thezorn's AAZ rebuild.

[bugnut]

I know this doesn't make a difference right now but I would move the LP wastegate line to the manifold.  Once you get some turbos that work that is going to be a lot of boost and it may be to quick.  By the time you see it you could well be in the 40-60 range.  When I added 2psi on the LP turbo I got 4-5psi at the manifold.

As for my boost, it is very quick.  Almost no lag at all.  The k14 takes care of that for me.  Comparing it to my single T3 it is light years ahead of the game.  The T3 was total lag.  Right now I make boost in every gear.  I will have to make a video of it someday and post it up. 

[RadoTD]

His boost isn't going to hit 40 with fuel for 600deg. Certainly not without him flogging it at least

I hover around 6-10psi part throttle around 2000rpm just cruising with traffic. 7psi coasting at 3000rpm and rolling on the throttle from that, I hit 20 (where I've got my wastegates set right now) in under 2 seconds. My EGT's are much higher... I'm easily able to hit 1200, with fuel for only about 6-8psi . Still no intercooler right now

[Thezorn]

His boost isn't going to hit 40 with fuel for 600deg. Certainly not without him flogging it at least

I hover around 6-10psi part throttle around 2000rpm just cruising with traffic. 7psi coasting at 3000rpm and rolling on the throttle from that, I hit 20 (where I've got my wastegates set right now) in under 2 seconds. My EGT's are much higher... I'm easily able to hit 1200, with fuel for only about 6-8psi . Still no intercooler right now

This is true, even before with just the K14 I would maybe hit 800-900 degrees on a long hill pull at 17 psi with the intercooler. That was with the 1/4' autometer probe that was very slow acting. Who knows if that what I was actually at..

[Smokey Eddy]

His boost isn't going to hit 40 with fuel for 600deg. Certainly not without him flogging it at least

I hover around 6-10psi part throttle around 2000rpm just cruising with traffic. 7psi coasting at 3000rpm and rolling on the throttle from that, I hit 20 (where I've got my wastegates set right now) in under 2 seconds. My EGT's are much higher... I'm easily able to hit 1200, with fuel for only about 6-8psi . Still no intercooler right now

What have you been doing in my absence!
I could brag about my EGT's

[Thezorn]

So, good news. Turns out it was the turbos/wastegates that were the problems. Replaced them with some new (used) turbos that were in good working order, and boom, it boosts now. The car sounds unreal, first, right off take-off you hear the K14 spool, then at about 2k the K24 spools up nice and loud.  
EGTs are suuuper low, cruising at 100kmph, with about 5-8psi boost im at about 325 degrees, on a bit of a hard pull ill go up to about 6-700 degrees at about 15-17 psi.
Gave it a couple fairley hard pulls up to about 4k, it sure set me back into the seat and hit 17 psi very fast. I also notice it is alot quiter traveling at highways speeds now compaired to just having the K14.
I am definatley very happy to finally be able to drive this car!!

On the bad news side, my wipers decided to stop working..but only the front ones, the washer still works, and the rear wiper/washer still work. Im guessing it could only really be either the switch, the relay, or the motor istelf. I havent had time to test the circut yet to see if the motor is getting powered but Ill try to tomorrow.

[Thezorn]

After all the problems I went though ordering the correct clutch disk I was wondering if you guys could help make a list of the MK3's that come with the 24mm input shafts?

Did the early 1.9 IDI's have them? from my understanding they didnt and actually had the 22mm. I ran into this problem when I was building my engine, I ordered the clutch disk for my car (93 AAZ golf) and was sent what I thought was the correct disk. It wasnt, it was for the 24mm input shaft and my tranny is a 22mm.
After realizing this I went and talked to the dealer about my car and he said that he had actually swapped out the OG diesel (ATH) tranny to one from and MK3 gasser (1.8l) believed to be a AUG. After driving it I realized this wasnt the case.

From the RPMs I see driving at 100kph (2725 ish) I beleive it is actually an AGS. AG- are the only letters that are visable on the bell housing on the tranny now. Now if it is an AGS, that means its from an MK2 1.6td vehicle and they had the 22mm input shafts.

Hear is the part I dont understand. When I sourced out a clutch disk I had the guys find the one for my car first (93 AAZ), then I asked him to check if the 1.8l clutch disk was the same, Sure enough it was, and they both were listed as 22mm splines or 13/16 of an inch. He also said that the 2.0l was the only one with a different part number, im guessing that one is for a 24mm input shaft.
I know that 93 was the first year of the new body style and the 1.9td engines, I also know that 93-94 were the same, 95 had a few changes and 96-98 had alot more changes (including the swap to TDI)

Could it be that 93 to 94 had the smaller 22mm input shafts and then 95 and so on they were upgraded to the 24mm? I really have no idea here and am mostley shooting for answers, so please correct me if im wrong!!

Im sure having this info available would be great, and very helpfull to alot of people, please add in what you know!

[RadoTD]

I'm 90% sure that the MK3 8V transmissions have the 24mm input shaft; AMC, DFQ and CHE codes. 3.67 final drive with a stock .8 5th gear (easily swappable for a .75 to give you a bit higher ratio). The MK2 16V trans's did as well, but you don't want to go there. 3700rpm at 120km/h

I'm not sure what trans the 93's came with or what size the input of the ATH is though..

[R.O.R-2.0]

rule of thumb.. if its 1.9, or 2.0 litres, its got a big input shaft. think of the 1.9 and 2.0 as the BIG BLOCKS, even tho they arent technically.

and anything under 1.8 or smaller, got a small input shaft.

and that goes for everything ive taken apart so far.. dont have any experience on the canadian TBI 1.8 jettas.. but there probably 22mm shafted..

[Thezorn]

rule of thumb.. if its 1.9, or 2.0 litres, its got a big input shaft. think of the 1.9 and 2.0 as the BIG BLOCKS, even tho they arent technically.and anything under 1.8 or smaller, got a small input shaft.

and that goes for everything ive taken apart so far.. dont have any experience on the canadian TBI 1.8 jettas.. but there probably 22mm shafted..

This is what I thought, but the stock replacment clutch disk for my 93 AAZ, which should have had the ATH trans, was listed as a 210mm diameter disk for a 22mm input shaft. So like I was thinking maybe the early MK3's, 93-94, still had the smaller 22mm input shaft like the MK2's, besides the 2.0L.

[vanbcguy]

Lots of weirdo stuff on the early Canadian Mk III's, I don't think there's really any way to say for sure exactly what you're going to find.  The '93-94 cars don't fit too many of the "rules" for the body type.

[Thezorn]

Lots of weirdo stuff on the early Canadian Mk III's, I don't think there's really any way to say for sure exactly what you're going to find.  The '93-94 cars don't fit too many of the "rules" for the body type.

Haha Very true!
Took the car for a 200km ish trip today, did really well. Blew off one coupler during the ride, and of course it was the one on the bottom turbo underneath everything else. After a while I was back on the road and didnt have any other problems.
Have about 350km on it so far.

[Thezorn]

Have just under 1500kms so far from drive back and forth to work this week. Couple interesting things here.
On a super hard hill pull at 18 or so PSI I dont see EGT's any higher then 550F. This could mean 2 things, the compounds and the intercooler are making a HUUUUGE difference in EGT temp, ooor, I barley have any fuel. Im sorta leaning towards the lack of fuel.
I really dont think doing the gov. mod is what I want to do. So Im going to either get giles to build my pump or Im going to try and rotate the throttle arm? thing. My fuel screw is already in as far as it will go without the idle being to rediculously high (1050-1100)

I do think the compounds have at least a bit to do with the EGT situation, IIRC my EGTs and highway cruising with just the K14 and intercooler were about 450-500F. Now with the K24 and K14 and intercooler they are about 300F (at 100km)

All I need now is more fuel so I can add more boost.

[rallydiesel]

If you can build a compound set-up then surely you can tune your pump for more fuel! 

[keaton]

you need more fuel

saying your pump work great with one turbo (k14, iirc) a XX psi doesn't meant that with the other turbo (k24) at the same PSI.

now your moving more air (lbs/min) you need more fuel. go turn that fuel screw up a 2 or 3 turns, and make a video 

[RadoTD]

So Im going to either get giles to build my pump or Im going to try and rotate the throttle arm? thing. My fuel screw is already in as far as it will go without the idle being to rediculously high (1050-1100)

My throttle arm is rotated back I think 3 notches already and will need multiple more once I get around to tuning my pump.
Before you pull the last arm off, make a good mark with a knife or something where your arm is set. I would do 1 or 2 notches at a time and start the car/get it idling properly before getting all the springs back on. Remember as well that rotating the arm back means you can back out the full throttle stop screw on the front of the pump too!

Your pump is an AAZ, right? It's a real PITA to get the springs on and off. Set aside hours to get it done. You'll use them all. Take lots of pictures before you pull it apart; it'll save you lots of time staring and scratching your head at how the arms go back on. I don't even have all the springs on my pump anymore.