Recent Posts

31

IDI Engine / Re: 4-slot rubber hard line clamp on AAZ

« Last post by zuhandenheit on June 04, 2026, 07:53:02 pm »

I had the same experience: am using just two clamps on my lines, was not able to get the four-seat clamp to fit. I've wondered if it's enough.

 (hello people nice to see you and be back after ... uh what 10 years?)

32

TDI Engine -General Info / Re: ALH into Vanagon, what injectors?

« Last post by fatmobile on June 04, 2026, 03:19:26 pm »

Probably not.
 Yours is an ALH and it calls these PD injectors, which was the next generation.
 The PD injectors are pushed by the cam, to way higher pressures than the ALH and bosch rotary pump.

33

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on June 04, 2026, 03:01:34 pm »

I have both covers (and a few 1.6 lower covers) here and I like the AHU one better.
 It looks stronger around the pully. Sounds like that makes it hard to use with the V-belt crank pully.
Makes sense, it's opened up a lot on the AAZ lower cover.
Glad he has someone local helping him with parts.
 These 1.9s are rare and can be hard to find parts for in the US, especially plastic parts.

Oh that motor mount is upside down, dang it.
 I fill the gaps in mine with urethane. Almost impossible to find the V-shaped heavy duty motor mount.
Parts geek said they had them for $35, then sent me the weak one they had for $10.
Refused to make it right so last time I bought from them.

 The head on the broken AAZ I'm playing with has a KS head on it.
 I really hope it survived,.. but a thrown rod can cause a lot of damage.

34

TDI Engine -General Info / ALH into Vanagon, what injectors?

« Last post by Gnarlodious on June 04, 2026, 10:22:08 am »

I am getting an ALH ready for my Vanagon, it is currently all stock (2002 Jetta). Is this the injector I need for a midrange power upgrade?
https://cascadegerman.com/product/pd150-tdi-injector-nozzle-set-wuzetem-1043/

35

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on June 04, 2026, 10:06:38 am »

i sold him some of these bits, the lower cover is off of the ahu that's currently in my car. I think the aaz and ahu lower covers are the same or close enough, i used the aaz one on my ahu because it was already trimmed for running a v belt. 1.6 lower cover is different, the split where it meets the upper cover is more of a straight line where the aaz/ahu has kind of a z pattern

Only remember ya saying TDI, don't know engine code. Had to open center hole for the cast 068 pulley. Might need to remove the metal ring to clear the V belt too. Need to dig out an alternator. 90A on Jabbit, same bracket, and had to custom make an adjustment arm. Going same route here.

And had to post this one.

36

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on June 04, 2026, 07:28:09 am »

Looks like you remembered to put the T-bolt in the waterpump before putting the alternator bracket on.
Ha. Hate it when I forget that after all these times.
Moving right along quickly.
 It looks great.
Took me hours to find the little standoff for the MK2 upper timing belt cover.
 But I got a chance to organize fasteners, inventory the hoard and did actually find one.


Is you lower timing belt cover from an AAZ or AHU?
 I'm thinking AHU.

Of course I remembered the "T" bolt.
After the alternator mount was on.

But you missed the upsidedown motor mount.

This thing has been apart and back together so may times now. Just wait till the next time it's apart to address that too. And that, and that ..

37

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by RabbitJockey on June 04, 2026, 06:52:20 am »

i sold him some of these bits, the lower cover is off of the ahu that's currently in my car. I think the aaz and ahu lower covers are the same or close enough, i used the aaz one on my ahu because it was already trimmed for running a v belt. 1.6 lower cover is different, the split where it meets the upper cover is more of a straight line where the aaz/ahu has kind of a z pattern

38

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on June 03, 2026, 11:00:04 pm »

Looks like you remembered to put the T-bolt in the waterpump before putting the alternator bracket on.
Ha. Hate it when I forget that after all these times.
Moving right along quickly.
 It looks great.
Took me hours to find the little standoff for the MK2 upper timing belt cover.
 But I got a chance to organize fasteners, inventory the hoard and did actually find one.


Is you lower timing belt cover from an AAZ or AHU?
 I'm thinking AHU.

39

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on June 03, 2026, 08:33:41 pm »

Did all the coolant hoses I can. Local parts store had all the hoses and even an NOS water pipe In Stock. 
OK, Parts store is in the second floor of MY shop.
Coolant necks and temp senders too.



And a Few more little things.
Injector line clamps, injector return hoses and NOS German Hella oil presure sender.

40

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on June 03, 2026, 08:24:11 pm »

Moving along... Last couple days work.

New pistons installed. New rod bolts etc.
Head is on and torqued. One notch MLS head gasket...


Intake installed, upper elbow in an NOS 068 from the hoard, rubber hose too.
Exhaust manifold on and torqued.
Didn't fully torque that turbo down, yet. Also need to dig out the correct support bracket for the 171 down pipe.




Moved on to fitting some 1.6TD oil return lines to the NOS oil pan. There were 2 pans, different angle on the fitting on pan and each used a different oil return tube.
Uncrimped the SS braided hose from the required return line to fit this pan. Taller block so it needs lengthening. New hose should be here tomorrow. 3 Otiker clamps at each end will be adequate.
Had to align the tubes.



Decided to use a -4 AN line for the oil feed to turbo. Line and all Stainless steel fittings arrived today. Still waiting for the SS banjo to -4 for top of oil filter housing, Stainless bajjo bolt too. Fitting for top of turbo to AN is steel. SS for that was elusive in my search. Well, did find one in Taiwan for a few bux but wasn't going to pay $20 shipping plus fees.