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Author Topic: AAZ Turbo Upgrade  (Read 261 times)

June 08, 2018, 12:51:08 pm

veector

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AAZ Turbo Upgrade
« on: June 08, 2018, 12:51:08 pm »
I'm having a tough time finding a good used k24 from a 1.6TD but stumbled on one from an old diesel audi 5000,  only catch is the flange is a 4 bolt rectangle instead of the trapezoidal one commonly found on the k14/k24 4cyl diesels.  Is there a manifold that would allow me to use this turbo or am I SOL?

My little Ko3 doesn't like how much exhaust my giles pump is pushing though it.


1981 Jetta D
1997 Jetta TD

Reply #1June 09, 2018, 09:27:14 am

Gizmoman

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Re: AAZ Turbo Upgrade
« Reply #1 on: June 09, 2018, 09:27:14 am »
A chunk of steel thick enough to sink the bolt heads into can make most any turbo match up to most any manifold.
Obviously you'd have to orient the bolt pattern to be inside or outside the adjacent flange seal areas and still end up with proper turbo orientation for your application - typically with the oil drain facing down (6 o-clock). You'll also have to clock the scroll intake to it's ideal location as well. Most turbos will allow the two halves to be rotated as needed.

With enough fortitude it can be done. Before you put the effort into it though, make sure it's the proper turbo for your engine and more specifically, the pump. I believe Giles builds the IP specific to the turbo. Did you tell Giles what turbo you were running? If you told him it was a K-03 and it seems to be fueling too much, possibly you have turbo issues.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #2June 09, 2018, 11:44:08 am

veector

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Re: AAZ Turbo Upgrade
« Reply #2 on: June 09, 2018, 11:44:08 am »
That's what I was thinking, saw a post here on running a holset turbo on the old trapezoidal manifold using a spacer/ adapter.

As for the pump,  it was built to fuel 30psi but had giles turn it down to what the Ko3 likes (15psi max)

He even mentioned that the Ko3 hot side gasses will "back up" causing higher EGTs and CHTs and I'm experiencing that now with hot summer air, no intercooler and a tiny turbo.
1981 Jetta D
1997 Jetta TD

Reply #3June 09, 2018, 05:28:31 pm

Gizmoman

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Re: AAZ Turbo Upgrade
« Reply #3 on: June 09, 2018, 05:28:31 pm »
Your on the right track replacing the tiny turbo with something larger.
Find a chunk of 1" steel plate and go for it.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #4June 09, 2018, 08:36:09 pm

RunninWild

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Re: AAZ Turbo Upgrade
« Reply #4 on: June 09, 2018, 08:36:09 pm »
The k24 came with a rectangle flange on the vw diesel as well. I'd just track down a rectangular manifold, they usually got for like $50.

Reply #5June 10, 2018, 01:47:15 pm

RabbitJockey

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Re: AAZ Turbo Upgrade
« Reply #5 on: June 10, 2018, 01:47:15 pm »
im not sure which vw diesel ever came with a rectangular flange?


if you want an upgraded stock turbo id go with the t3, its more efficient at higher boost pressures. if you want a real upgrade use a newer turbo like an he200wg
98 Pontiac Grand Prix GT:stock daily
 81 Jetta: in progress 1.6td, ported head, holset turbo.
81 Rabbit:AAZ, hybrid T3 turbo, Giles pump, lightened fw, and yellow clutchnet clutch.

Reply #6June 13, 2018, 10:51:17 pm

RunninWild

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Re: AAZ Turbo Upgrade
« Reply #6 on: June 13, 2018, 10:51:17 pm »
you're right, not sure what I was thinking lol

+1 for he200wg

Reply #7June 20, 2018, 04:13:12 pm

veector

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Re: AAZ Turbo Upgrade
« Reply #7 on: June 20, 2018, 04:13:12 pm »
Thanks for all the info, been doing some research and it seems the HE200WG is a good choice.  Anyone have a source on them?  The reason i'm thinking K24 is that i've got a link on a NOS OEM one some dude has had in his possession since the 80s and the price is right!


Planning on running a PD manifold and an intercooler as well but will be hard pressed to leave the boost at 15psi :D
1981 Jetta D
1997 Jetta TD

Reply #8June 21, 2018, 09:33:43 am

Gizmoman

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Re: AAZ Turbo Upgrade
« Reply #8 on: June 21, 2018, 09:33:43 am »
I purchased my HE200 from Alcaid - a valued member of this forum

The only issue I had to deal with is the boost-pot is hard mounted to the intake scroll. If you have to re-clock the exhaust side of the scroll, you'll need to make your own mount. Also, there is a tiny pin in the mating flange between the two halves which will need to be removed if you have to change the clocking. Here is a shot of the re-configured pot (and rod) - a real PITA but it works.





Your situation may be quite different - hopefully :)
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #9June 21, 2018, 04:06:11 pm

veector

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Re: AAZ Turbo Upgrade
« Reply #9 on: June 21, 2018, 04:06:11 pm »
Nice thanks for the pic and info!

Im guessing you're need to clock is due to it being installed in a Vanagon. 

Even a custom actuator rod by the looks of it?

Looking into getting a holset from Alcaid. 

Anyone have opinions/ experience with the audi 5000TD K24?  Seems to be a t25 flange, dont know much else.
1981 Jetta D
1997 Jetta TD

 

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