k24/t3 on AAZ concise and simple!

[burn_your_money]

You might also have to grind a bit away from the intake manifold to make it all fit.

You can modify your current downpipe by cutting off a bit of the bottom of the flange and drilling two holes. A custom mandrel bent one would be better though.

Also, you will need to change the intake boot from the filter to the turbo. You might need to go custom here.

[CrazyAndy]

Why not just pick up a good used k24or t3 intake boot?

[tdotdub]

“THEZORN” so since the ports are different do I just continue using the AAZ intake manifold?
I have a pd150 manifold with egr in a box but want to use that on my tdi, im pretty sure the aaz will never be as fast as the tdi,so I rather use it there…..
I bought a nice T3 turbo with the 1.6td intake and exhaust as well as oil line from 1.6td.
So far I gather that I can either change the oil pan to a 1.6td one and block off the aaz oil return (http://www.brickwerks.co.uk/index.php?page=shop.product_details&category_id=59&flypage=flypage.tpl&product_id=333&vmcchk=1&option=com_virtuemart&Itemid=3) BUT will I loose any oil capacity? or take it to a hydraulic shop and have them make a custom line in between. Anyone know roughly how much longer it has to be? Or do I have to mock it up first and than take it to them?

this looks good, but having doubts having it shipped from the UK. http://www.brickwerks.co.uk/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=332&category_id=59&vmcchk=1&option=com_virtuemart&Itemid=3
I do plan on intercooling it once I fix some other issues first,I want to be pushing 24 psi reliably,plus the aaz is not egt friendly I read.
I really like what “chrisg” did, chopping off and welding it on seems fairly straight forward! might try that.
I didn’t think about the intake boot, but ur right,its bigger on the turbo side,ill get one…..i put a cone air filter on the one I have now, holly is it LOUD! As far as exhaust going to go with a custom mandrel bent one, 2.5”.
My clutch is slipping at 18 psi on the k14 now, but hopefully the slower spool of the t3 will help with that. Its weird, I don’t really see others sliping their clutches with good power, is it just my clutch or you guys upgrade to something? Should I replace with a new oem clutch and assume it will hold with a fresh pressure plate….
This is in a mk3 cabrio btw.

[RabbitJockey]

“THEZORN” so since the ports are different do I just continue using the AAZ intake manifold?
I have a pd150 manifold with egr in a box but want to use that on my tdi, im pretty sure the aaz will never be as fast as the tdi,so I rather use it there…..
I bought a nice T3 turbo with the 1.6td intake and exhaust as well as oil line from 1.6td.
So far I gather that I can either change the oil pan to a 1.6td one and block off the aaz oil return (http://www.brickwerks.co.uk/index.php?page=shop.product_details&category_id=59&flypage=flypage.tpl&product_id=333&vmcchk=1&option=com_virtuemart&Itemid=3) BUT will I loose any oil capacity? or take it to a hydraulic shop and have them make a custom line in between. Anyone know roughly how much longer it has to be? Or do I have to mock it up first and than take it to them?

this looks good, but having doubts having it shipped from the UK. http://www.brickwerks.co.uk/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=332&category_id=59&vmcchk=1&option=com_virtuemart&Itemid=3
I do plan on intercooling it once I fix some other issues first,I want to be pushing 24 psi reliably,plus the aaz is not egt friendly I read.
I really like what “chrisg” did, chopping off and welding it on seems fairly straight forward! might try that.
I didn’t think about the intake boot, but ur right,its bigger on the turbo side,ill get one…..i put a cone air filter on the one I have now, holly is it LOUD! As far as exhaust going to go with a custom mandrel bent one, 2.5”.
My clutch is slipping at 18 psi on the k14 now, but hopefully the slower spool of the t3 will help with that. Its weird, I don’t really see others sliping their clutches with good power, is it just my clutch or you guys upgrade to something? Should I replace with a new oem clutch and assume it will hold with a fresh pressure plate….
This is in a mk3 cabrio btw.

i think aaz and tdi should perform quite similarly with similar mods, the thing with the tdi is that it comes factory with bigger pump head and intercooler, along with it all being electronically controlled.  i think either engine will benefit from a better intake.  but other wise yes keep your current intake manifold.  on my 1.6 with k24 at 25psi the clutch started slipping, i think any turbo diesel with increased performance suffers from this, the stock clutches are made for 70hp at the most...

[libbydiesel]

The 1.9 blocks are taller than the 1.6 blocks, so the 1.6 oil return line might not be long enough to reach the 1.6 pan on a 1.9. 

[Blocksmith]

i think aaz and tdi should perform quite similarly with similar mods, the thing with the tdi is that it comes factory with bigger pump head and intercooler, along with it all being electronically controlled.  i think either engine will benefit from a better intake.  but other wise yes keep your current intake manifold.  on my 1.6 with k24 at 25psi the clutch started slipping, i think any turbo diesel with increased performance suffers from this, the stock clutches are made for 70hp at the most...

Bummer.... guess I should look into a better clutch for when I get around to the 'power' build I'm planning. Any recommendations on an upgraded clutch setup?

[chrisg]

You might also have to grind a bit away from the intake manifold to make it all fit.

You can modify your current downpipe by cutting off a bit of the bottom of the flange and drilling two holes. A custom mandrel bent one would be better though.

Also, you will need to change the intake boot from the filter to the turbo. You might need to go custom here.

there is no need to change the intake manifold.... just the little elbow on the top

[nathan_b]

You might also have to grind a bit away from the intake manifold to make it all fit.

You can modify your current downpipe by cutting off a bit of the bottom of the flange and drilling two holes. A custom mandrel bent one would be better though.

Also, you will need to change the intake boot from the filter to the turbo. You might need to go custom here.

there is no need to change the intake manifold.... just the little elbow on the top

the turbo coldside physically hits a casting mark on the aaz intake manifold.

[chrisg]

oh ya, i just quickly fixed that with a small file and 5 minutes.

[jimbobpolo]

My polo with 1.9td and k24 turbo..
http://m.youtube.com/watch?v=cl0mvejiWaU