Intake JX/AAZ mongrel help

[AAZTristar]

EDIT: I changed the subject heading to reflect new info needed.

I've got a 89' Syncro Tristar that came from the factory with a 1.6 JX TD engine that was converted to an 1.9 AAZ. As far as I can tell from the receipts the PO had from the shop that did the conversion all the JX bits were used.

I want to add some gauges like a EGT, boost,etc. and want to have the needed gaskets on hand when I take apart the intake/exhaust system to drill the hole for the EGT probe. And would like to have new gaskets anyway for a nice tight setup.

Having trouble finding part numbers for the exhaust manifold gasket, intake manifold gasket, etc.for the JX TD. Vagcat does not list these as far as I could find.
Also, where is a good source for these gaskets?

Another question is the port matching between the JX bits and the AAZ head. Are they the same shape?

Thanks for any help and advice on this project.

[vanbcguy]

The exhaust gaskets are the same for all 8V VW 4 cylinder engines; you can get a gasket for anything and it'll work fine.  The late '90s AHU ones will probably be the easiest to find at a parts store - ie look for a '98 Jetta TDI.

Intake ports changed from oval shape to D shape with the AAZ.  The AAZ and all the TDIs use the D-shape while the JX and all the other 1.6 and 1.5 diesels use oval ports, so technically the JX manifold is not a good choice for the JX as the ports won't match up shape wise, though there are folks on here who have done it successfully.  It's just not optimal.

Gasket-wise for the intake you're going to need to sort out what intake you have.  If it's an AAZ intake then again you can just get an AHU gasket and be good to go.  If it's the JX manifold then things are a little trickier - I'm not sure which would fit best, I'd probably use the same as whatever was in there.  The JX would have had a black overboost protection valve on the passenger side end of the intake which wouldn't have been present on the AAZ manifold.

[AAZTristar]

Thanks for the info, on closer inspection of the receipt from the shop that did the engine swap there is no mention of port work on the intake manifold, although there is a charge for a new #028-129-717D gasket. ( I should have looked at this receipt first, it lists the part numbers )
Looking that up I find it's a newer D shape port intake gasket.

Here's the best photo I have right now of the intake manifold (I know, not very good) but it shows the BOV. So, I'm guessing that I still have the original JX manifold. It will be interesting to see whats what when I pull the manifold.



If I source a AAZ intake manifold will I run into other fitment issues?

[vanbcguy]

I can't say for sure about fitment, you'd really want someone like Libby for that...  I'm not sure if the AAZ intake has the inlet in the same spot as the JX or not.

[libbydiesel]

In seeing your pic, it appears that you have the stock JX manifold with the mismatched ports...  None of the 1.9 intakes had the BOV.

You could potentially port the manfiold but there is precious little aluminum left for sealing by the bolts when you're done. 

The AAZ intake has the snorkel on top instead of in the center of the side like the Quantum/Vanagon (JX) manifold.  You could re-use the metal block-off plate from the top of your JX manifold and then have the snorkel welded to the center/side of the AAZ manifold.  A better option, IMO, would be to add an intercooler and orient your intake tract to take advantage of the AAZ inatke manifold inlet location. 

[AAZTristar]

Yep, any changes to the intake manifold will be done with views toward adding an intercooler. Luckily it's a Doka/Tristar I'm working with so there is the extra room above the engine vs a Vanagon.

From some of the reading I've been doing, there's talk of using a PD130 or PD150 intake for better air distribution into the AAZ head.
Any thoughts or tips to this mod?

[Rock3tman]

If you're adding an intercooler, you may want to look at the intake manifold for a 1X engine (028129713C)...It has the "D" ports and longer
runners that aid in breathing, and works pretty well for hooking up intercooler piping; my application is on a n/a 1.9 IDI engine in a 1981
Caddy.   May interfere with your turbo arrangement - 028129713E will work better if you have a "topmount"  turbo.   These two manifolds
take any AAZ/1X/1Y/AHU intake gasket I believe.   Put some locktite on the intake manifold bolts as all of mine backed out a bit and two
broke off inside the head    

I got mine from a place in Calif - Quality German Auto Parts for $50-60 IIRC.

[AAZTristar]

If you're adding an intercooler, you may want to look at the intake manifold for a 1X engine (028129713C)...It has the "D" ports and longer
runners that aid in breathing, and works pretty well for hooking up intercooler piping; my application is on a n/a 1.9 IDI engine in a 1981
Caddy.   May interfere with your turbo arrangement - 028129713E will work better if you have a "topmount"  turbo.   These two manifolds
take any AAZ/1X/1Y/AHU intake gasket I believe.   Put some locktite on the intake manifold bolts as all of mine backed out a bit and two
broke off inside the head    

I got mine from a place in Calif - Quality German Auto Parts for $50-60 IIRC.

After researching those part numbers and pursuing some other forums about this it seems I might be better off with another intake than an AAZ (better air flow to all four cylinders) like the PD130/150 intakes or a SDI snail intake.
Anybody have info where to source these intakes here in N/A?

Rock3tman, did you contact Q.A.P. directly? I didn't see any used intakes on their website.

Thanks for any help!

[Rock3tman]

yes, I asked if they'd take one off of their used motors they get by the crate from Europe

[vanbcguy]

After researching those part numbers and pursuing some other forums about this it seems I might be better off with another intake than an AAZ (better air flow to all four cylinders) like the PD130/150 intakes or a SDI snail intake.
Anybody have info where to source these intakes here in N/A?

There is pretty much always someone selling PD intakes over in the TDIClub classified section.  I got mine for a bit closer to $150 I think, but it came with a very nice stainless race pipe to replace the original bolt-on EGR valve, an EGR blockoff plate and a new gasket for the race pipe.

[AAZTristar]

New question. Will a pd105 intake work ok on the AAZ?