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91
Troubleshooting / Re: 1.6 TDi CAY engine - oil pressure concerns.
« Last post by ORCoaster on March 04, 2026, 06:53:48 pm »
I have to ask.  At what RPM are you measuring the pressures at the various points?  I think that 15 psi at the head would jump considerably if you ran it at 1,000 RPM.  I think that is the Bentley spec, but don't quote me on that.  I think the 15 psi at idle is acceptable if it rises upon acceleration. 
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Troubleshooting / 1.6 TDi CAY engine - oil pressure concerns.
« Last post by davegsm82 on March 04, 2026, 04:19:46 pm »
Hi, I've recently bought a car with the 1.6 CAY engine, it's got a blown turbo, this had been replaced by the previous owner with a brand new unit and evidently failed very quickly.

When I started the car at one point it did have a flashing oil light so I shut it down straight away, suspecting oil pressure issues.
I bought a pressure gauge, attached it to the oil pressure switch port and started up, it showed about 15 Psi.
I then disconnected the turbo oil feed (bare in mind the turbo is ruined) and connected the pressure gauge there, it showed about 30-40 Psi.
Finally I blocked the turbo oil feed on the block with a plain bolt and re-measured the pressure at the oil pressure switch, still 15 Psi.

Google seems to suggest that all of this is normal, and I'm starting to think the previous owner either had really bad luck or bought a really cheap turbo which failed immediately and they subsequently gave up on it.

I've got another Turbo from another 1.6TDi, not exactly the same unit but it's from the same series of engines, all feed, return, boost and exhaust piping will bolt right up. I'm willing to put it all together and try it, but has anyone got any experience with oil pressure issues on this engine? am I missing anything obvious?

Have also checked the oil filter for sparkles, none found, only a tiny amount of sludge, can't even find any rubber from the wet belt. Other than the lack of turbo and the alarming oil pressure light, the engine starts and runs well.

93
IDI Engine / Re: 4-slot rubber hard line clamp on AAZ
« Last post by fatmobile on February 27, 2026, 09:46:26 pm »
Yep, some parts for these are getting hard to find.
 Glad to hear you were able to find a supply of new ones, worth the wait.
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IDI Engine / Re: 4-slot rubber hard line clamp on AAZ
« Last post by ORCoaster on February 27, 2026, 04:43:19 pm »
Ahh this explains a lot about our hoarding behavior;

"I have found that you have to buy re-pop gear when it becomes available, not just when it is convenient."

I see stuff on Marketplace or CL and I just have to have it!!!!  Not that I need it right now, but I am sure I will in a year or 5. 

I did actually have the chance to replace a fuel line that had a micro hole in it, and it was pissing on the top of the engine and causing that cylinder to run poorly.  Bad pop-off pressure is the cause.   

It took me all of five minutes to walk into the shed, bring out a replacement line, and install it.  My son was watching me at the time and had to shake his head.  Who has replacement parts like that in their shed?   He asked.  I said all of us do.  Because it is the way!!!!
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IDI Engine / Re: 4-slot rubber hard line clamp on AAZ
« Last post by Otis2 on February 27, 2026, 12:02:39 pm »
Thank you for the link, @sgnimj96.

The Brickwerks hard lines came into stock recently, and I bought a complete set.

I'm very pleased, they fit perfectly together using all three stock VW clamps.

I just bled the system and ran it for an hour, no leaks. 

I will keep my old lines as spares, but with the clamps in place properly now, I doubt I will have cause to need them.

Highly recommended product.

Photos of old lines beside the new ones, and the new ones in place on my AAZ engine:

https://drive.google.com/file/d/1IAT4M_9vRNXVDvNX9E2YE6dDbwbUsCYl/view?usp=drive_link
https://drive.google.com/file/d/17qoKb5Br5zj6RMgTHPeiwDm7qt1Qwe2c/view?usp=drive_link
96
IDI Engine / Re: AAZ Vanagon finally going TDI but which one AFN or AHU?
« Last post by RockOcean on February 25, 2026, 06:44:20 pm »
I went with the AFN for the better injector nozzles, VNT15, and stouter IP.

It arrived from Quality German Auto Parts in LA to Southwest Montana in 2 days!

I had it shipped to my grocery store in town. And a friend picked it up for me. Will unpack it tomorrow!

ae7622ff-8e4e-4e6a-9873-60b8442d6736 by RockOcean.com, on Flickr

88649ca0-9912-4ca2-974d-16ac2ff097b8 by RockOcean.com, on Flickr
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IDI Engine / Re: AAZ Vanagon finally going TDI but which one AFN or AHU?
« Last post by fatmobile on February 25, 2026, 06:14:45 pm »
Nice, looking forward to pictures.
So which engine did you decide to start with?
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IDI Engine / Re: Can a good VW gasoline mechanic work on an IDI engine?
« Last post by ORCoaster on February 25, 2026, 06:14:31 pm »
I see Bentleys on Craigslist a lot.  Just might be your year and model they are selling.
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IDI Engine / Re: AAZ Vanagon finally going TDI but which one AFN or AHU?
« Last post by RockOcean on February 24, 2026, 11:25:10 am »
Hiya!

As an update I ended up going with a JX manifold with an adaptor plate (by Tim Shettle) to run the VNT15 or VNT17 turbo in the future. This will clear my early diesel carrier bars and work with the mount bracket that I have. Also will use the Turbo Exhaust Adaptors (also by Tim Shettle) so I can run the stock JX downpipe (sideways pipe on a Vanagon lol) which I am going to run straight out the back thru the bumper like a school bus.

I'm doing a stand alone wiring harness from Fast Forward Automotive in Canada using an ALH ECU tuned for 122hp & 200ft/lbs

I am hoping to run a Mk4 TDI instrument cluster from Andy and Syncro Sport in the UK but can not get a hold of them. I love this since I drove a 2003 Eurovan 10 years before I bought my Vanagon so that will be nostalgic for me :~ )

Also doing the TDI Input Shaft so I can run the Mk4 DMF and Clutch .

Will share photos of the build when the parts start rolling in. Engine gets here on Thursday!
100
IDI Engine / Re: Can a good VW gasoline mechanic work on an IDI engine?
« Last post by BleachedBora on February 24, 2026, 11:16:25 am »
Bentleys are very hard to find. I just checked all my vendors and they are out. You could get a 24 hour subscription to Erwin - it goes back to Mk3 so you'd get AAZ but 1.6 info is hard to find....
https://vw-us.erwin-store.com/erwin/showHome.do
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