Observe this intake...

[wolf_walker]

82 Caddy. Really not wanting a driver's side intake, lot of crap there already.

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[wolf_walker]

Well, I found an intake for what I was willing to pay I think, it's an EGR model but looks easy enough to blank off.
Don't think I'm going to find anything else in the timeframe I have to work with so it's this or nothing.
Now I have to cobble an intake hose and filter.

[CrazyAndy]

Any pics?

[wolf_walker]

Shortly yeah, on phone. Cleaning up my old TD air box to use with this intake.

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[wolf_walker]

https://www.box.com/s/zqbkfwcpw05l75grcg3o

https://www.box.com/s/a3gj63uivqmeqb66fd31

https://www.box.com/s/co6gl1n3u8w1qq72cs6n

Looks easy enough to block off the EGR.  Isn't as aesthetically pleasing as the non-EGR model but such is life I guess.

I cleaned up my old Jetta TD airbox that I used when the AAZ was turbo'd last, got to find a hose to connect intake to
airbox, don't know what size the intake inlet fitting is.

[Rock3tman]

Wolf -
I think the stock 1.6TD airbox is close to 2.5" diam. at the outlet (...and just about the same as the black fitting on the manifold).  I've trial fit a silicone connector to leftover 2.5" aluminum intercooler pipe that will likely be used to connect to a 2.5" K&N cone filter as I don't have a stock 1.6TD airbox available.   

Where/how are you locating the fuel filter with the new manifold?  I'm putting the non-EGR version of that manifold into a 1982 caddy and will be moving the filter to just fwd of the passenger strut housing & looking for some photos/ideas of best way to do
this.

[wolf_walker]

Wolf -
I think the stock 1.6TD airbox is close to 2.5" diam. at the outlet (...and just about the same as the black fitting on the manifold).  I've trial fit a silicone connector to leftover 2.5" aluminum intercooler pipe that will likely be used to connect to a 2.5" K&N cone filter as I don't have a stock 1.6TD airbox available.   

Where/how are you locating the fuel filter with the new manifold?  I'm putting the non-EGR version of that manifold into a 1982 caddy and will be moving the filter to just fwd of the passenger strut housing & looking for some photos/ideas of best way to do
this.

Well, the TD airbox was in there back when the motor was still turbo'd and I think I had the filter on the back side, sorta, of the pass side strut tower, but I'm open to it being elsewhere.
Figured I'd trial fit the box this weekend and see what it looks like.  Figures I just replaced all my fuel lines with nice cloth covered German stuff, oh well.
I'd use a cone filter tucked somewhere if there was one I could trust that didn't cost a fortune.  Can't go but so wrong with a factory filter I figure, and the box is laying around, so..

What motor are you using?  I figured I was the only one using one of these in NA trim by choice.
I envy you the non-EGR.  I haven't ruled out cutting it off and having the hole welded up if I can find someone willing.
But I'll probably wuss out and just blank it off at the valve flange.

[Rock3tman]

Engine is a 1.9 n/a (engine code 1Y) that just blew a headgasket @ 7,000 miles due to a cracked thermostat housing that split apart.   I believe it to be a new crate engine from VW - not a rebuild.   Funny thing is that the head doesn't have any markings on it (part number, mfg, date stamp).  Pistons are marked with the KS stamp and the seller claimed that it was a VW industrial engine: the Bosch pump looks funny to me as it has no manual fuel advance lever next to the engine block and some sort of solenoid on the front side with a small metal tube that goes to the top of the pump by the fuel inlet.

<<anyone>> Does the plastic camshaft splash shield for 1.5/1.6 engines fit on a 1.9 with the different valve cover mounting?  thx

[wolf_walker]

Your pump sounds like mine, Google KSB, dodge trucks have them. I believe the baffle will fit, I have one to install here shortly.

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[wolf_walker]

Well my airbox is 2 3/4" OD, will see next week what the intake is.
I suspect I'm going to end up with a silicone 90 on the intake and flexible exhaust tubing for the short run to the intake.


Rock3tman, are you running 1.6 timing and accessory stuff or a full 1Y setup?
We have essentially the same motor, mine is a de-turbo'd AAZ.

[Rock3tman]

1.6 n/a timing belt cover spaced with washers & a short flat bar piece on the mount that's by the injection pump.
1.6 n/a alternator mount & v-belt setup (crank pulley, waterpump pulley, & alternator pulley); no a/c.   Did 1Y come with a serp setup initially?

I'm assuming that crank sprocket, injection pump & cam sprockets, and tensioner is stock 1Y/AAZ stuff, also thanks for the tip on oil shield fitment.

 

[wolf_walker]

Not sure on the serp belt to be honest, mine is all 1.6 stuff, mix or A1 and A2.

If you stall a few weeks I can tell you for sure on the oil shield, but I'm almost sure it'll just take
some fiddling with at worst, the basic shape of that stuff is still the same up there.  I saw one
for an AAZ/1Y in the parts catalog awhile ago but didn't note the part number.

Are you running the 1Y CCV setup or the 1.6 stuff?

[Rock3tman]

I put the head back on Friday w/ ARP studs, torqued to 45, then 85, then 125 per their sequencing & data sheet...man, it really felt like a lot of force!!!  I'll pick up a 1.6 oil shield this week and see what I've got for fitment issues- hope to be running by next Thurs or so.  Just need to hook everything back up, relocate fuel filter and replace fluids.

The CCV is a 1.6 n/a hockey puck that will now go into the fitting on the 1Y (non-EGR) intake instead of the old 1.6 n/a manifold with mismatched port & runners...

[wolf_walker]

Cool deal, there's a plastic Jose going down to the front of the block for the stock 1Y CCV stuff as well.

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[wolf_walker]

Intake acquired, now how do I get the EGR leavings out of it..  lol


The TDI guys seem to burn it out, wonder if letting it sit in a bucket of biodiesel for a few days will soften it up enough
to spray away?