Author Topic: Vanagon Syncro AAZ to AHU mTDI Libby pump  (Read 5711 times)

March 31, 2021, 01:09:38 am

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Vanagon Syncro AAZ to AHU mTDI Libby pump
« on: March 31, 2021, 01:09:38 am »
I thought I'd start up new thread about an engine swap I'm about to begin on a friend's '86 Westfalia hightop Club Joker Syncro.  It currently has a tired AAZ that has ok power, but is rough running and smokey when cold, and just doesn't have the oomph needed for this heavy rig.

I just ran up to Tacoma to pick up a fairly low mileage AHU shipped from Quality German in SoCal.  Yes, I know they have a checkered history, but the transaction was easy and professional.  My friend also wanted a low mileage engine, and those don't exist over here any longer.   The van has a nice liquid to air IC that I just completely renovated, but I'm not sure what to do with the exhaust, as in carry over the AAZ manifold and turbo, or figure out something else with the AHU stuff.  I bought one of Libby's last 12mm mTDI pumps, which I also have on my own ALH Vanagon.  That van was used to haul this AHU today. 

Any recommendations for a replacement exhaust manifold and turbo arrangement?  My ALH has a generic T3 flanged manifold with a custom adapter and GT2052 turbo.  It's a great setup, but it would require that I completely redo the IC and exhaust plumbing on this AHU.  I'd rather use one of the stock exhaust manifolds and bolt a different turbo on that, which hopefully would just need some exhaust plumbing work. 

Thoughts? 



'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #1March 31, 2021, 01:19:07 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #1 on: March 31, 2021, 01:19:07 pm »
I forgot that the AAZ has a JX 1.6TD exhaust, so I believe the turbo is a K14.  I think it needs to be rebuilt, so perhaps I'll just look for a new K14 and call it good.
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #2April 01, 2021, 05:59:30 pm

libbydiesel

  • Global Moderator
  • Veteran

  • Offline
  • *****

  • 3416
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #2 on: April 01, 2021, 05:59:30 pm »
The AAZ K14 is decent. 

I look forward to hearing more.

Reply #3April 01, 2021, 09:14:24 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #3 on: April 01, 2021, 09:14:24 pm »
I dropped the pump bracket off for machining today.  I stripped the AHU down yesterday, and overall it looks pretty good, but the intake ports were extremely occluded with soot.  Eliminating the EGR will resolve that.  I'll be putting in an order for general maintenance stuff I want to do while I've got the engine out--all the usual suspects including the pilot bearing. 

'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #4April 01, 2021, 11:26:03 pm

libbydiesel

  • Global Moderator
  • Veteran

  • Offline
  • *****

  • 3416
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #4 on: April 01, 2021, 11:26:03 pm »
At this point I'd recommend the Dual Mass Flywheel and for installing it you'll need the TDI Vanagon input shaft. 

Reply #5April 03, 2021, 03:02:59 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #5 on: April 03, 2021, 03:02:59 pm »
Do you know of a good supplier for the flywheel and input shaft?
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #6April 03, 2021, 06:49:34 pm

libbydiesel

  • Global Moderator
  • Veteran

  • Offline
  • *****

  • 3416
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #6 on: April 03, 2021, 06:49:34 pm »
The last DMF I got from Amazon for $215 shipped.  The 17-050 kit fits fine with the TDI Vanagon input shaft.  I think that T3 Technique might sell the shaft, but I have not purchased it there.  I have purchased them here:

https://www.vwbulliparts.de/vw-t3-kupplungsdorn/getriebeeingangswelle-tdi-umbau-auf-org-golf-tdi.html

Reply #7April 03, 2021, 07:11:06 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #7 on: April 03, 2021, 07:11:06 pm »
Thanks, I just found a 17-050 on ebay for $215.  I assume the stock Vanagon TO bearing will work with this pressure plate.  Any clearancing needed for the factory diesel bellhousing?  I honestly know absolutely nothing about DMFs, and hadn't budgeted for this expense, but it sounds like solid insurance to help preserve the precious trans in this van. 
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #8April 03, 2021, 07:45:23 pm

libbydiesel

  • Global Moderator
  • Veteran

  • Offline
  • *****

  • 3416
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #8 on: April 03, 2021, 07:45:23 pm »
As you say, I think the DMF is good protection for the trans.

There is a small a mount of clearancing required in the bell-housing.  I've done two of them and although the bell-housings are not all exactly the same, the area that needed attention was basically the same.

Here's a pic of the most recent one I did:


I used a rotary rasp.  The nose of the stock DV starter will pinch the edge of the flywheel also, when bolted up.  A little grinding at the nose will fix it.  The TDI starter with adapter does not suffer from that issue.

Yes, the diesel vanaogn throwout bearing will work with that pressure plate.  You'll need to mark TDC.

I'm not sure if I sent this to you before, but this is the area of the timing belt backing plate that needs to be removed.  It needs to allow the boss that is cast into the nose of the pump to rotate for timing adjustment:

 
« Last Edit: April 03, 2021, 08:09:27 pm by libbydiesel »

Reply #9April 12, 2021, 08:12:59 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #9 on: April 12, 2021, 08:12:59 pm »
I dropped the pump bracket off at a local machine shop a couple weeks ago, but they got back to me today to say that they would have to build a jig and bill me for at least two hours @ $100 per.  That seems kinda silly for what it is, so I picked it up and will try my hand at chucking it onto my lathe bed and using the four jaw as a fly cutter...or whatever else I can find to cut a centered 68mm hole.

This site really bothers my browser, which constantly kicks me out of login status. 
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #10April 12, 2021, 09:53:45 pm

ORCoaster

  • Moderator
  • Veteran

  • Offline
  • ***

  • 4384
  • Personal Text
    Restoring a Caddy as time and weather allows
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #10 on: April 12, 2021, 09:53:45 pm »
What Browser are you using?  I use both Edge and Chrome and never have that sort of problem.

Reply #11April 14, 2021, 01:55:38 am

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #11 on: April 14, 2021, 01:55:38 am »
I'm using Firefox that I recently updated, which caused all these issues.  Prior to that I would get periodically bumped out of my logged in status, but my credentials were cached and I could re-log in.  Now, the browser doesn't like the security settings of the log in process here, so it won't allow my credentials to be cached.  It's gone from slight annoyance to downright unpleasant. 
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)

Reply #12April 14, 2021, 10:47:05 pm

ORCoaster

  • Moderator
  • Veteran

  • Offline
  • ***

  • 4384
  • Personal Text
    Restoring a Caddy as time and weather allows
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #12 on: April 14, 2021, 10:47:05 pm »
I would try a session on Chrome just to see what the performance is compared to Fired Farts.


Reply #13April 30, 2021, 12:25:25 am

westyventures

  • User+

  • Offline
  • *

  • 45
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #13 on: April 30, 2021, 12:25:25 am »
I have a jig set up for my Smithy mill/lathe, $50 to machine the bracket, should you or anyone else need it done.
Karl Mullendore
www.westyventures.com

Reply #14June 09, 2021, 02:43:54 pm

Zeitgeist

  • Junior

  • Offline
  • **

  • 90
  • Personal Text
    Rule Cascadia
Re: Vanagon Syncro AAZ to AHU mTDI Libby pump
« Reply #14 on: June 09, 2021, 02:43:54 pm »
Thanks Karl, I took you up on your offer even though I hadn't even seen this post.  The pump is mounted and awaiting a timing belt. 

I of course didn't bother to mark TDC when I was tearing down the engine, and much to my surprise there aren't any hash marks on the crank or flywheels from either the AAZ or AHU.  Since I pulled the bellhousing to install the DMF input shaft, I'll use it to mark the new flywheel for TDC, and I guess I'll use a dial indicator through the injector hole to determine crank TDC.  Kinda annoying, but doable.
'87 300TD (OM606)
'90 300D (OM602)
'89 Vanagon Bluestar (ALH)
'01 EV Weekender (AXK)
'04 Passat Variant (BHW)