k03 turbo - manifold mismatch

[zuhandenheit]

I went to great pains to get a 3 bolt AAZ k03 manifold. The one that I've got was shipped across the ocean.

But I've found that this manifold and my turbo don't quite line up.





Sorry about the blurry picture.

There's a little dot on the turbo exhaust flange, directly under the top bolt hole. That's where the hole would need to be for the manifold and turbo to bolt together. I'm thinking about drilling a hole there and making an elongated slot.

I hate to drill into the turbo, but I don't have any other ideas - the manifold would be harder or impossible to modify, I think; and there's no way to make an adapter plate, because the bolt holes are so close together. Any ideas?

[libbydiesel]

Irfanview is free and lets you resize/resample pictures so it's not so painful to the folks you are petitioning for help.

The AHU/1Z K03 has a different turbine inlet bolt pattern, exhaust housing shape and wastegate from the AAZ K03.

[zuhandenheit]

My apologies for the big pictures. It should be fixed now.

This is an AHU turbo - I had figured that out before, and forgotten until you reminded me.

I have a drill press - would it make sense to modify the turbo as I suggested?

[GEE-BEE]

I have a ahu turbo and exhaust manifold not needed

I also have a pd150 rh facing intake, just back from strip clean

just needs race pipe egr delete and ready for powdercoat

let me know..

[zuhandenheit]

Thanks GEE-BEE! An issue is that this engine is going in a vanagon, and afaik, the AHU manifold will have the turbo in the way of a motor mount (I'm pretty sure that I already have an AHU manifold, in fact, and ordered this AAZ manifold expecting that it would mate to the turbo!)

[libbydiesel]

Also bear in mind that the AHU triangle is flipped relative the AAZ one.  I believe that if you just drill the hole you propose you will very much interfere with the driver's side bracket.  Also, the exhaust will be flipped from the normal vanagon direction which can actually make exhaust plumbing easier.  I think Karl M. sells an adapter for that turbo/manifold combo that mounts the turbo in the direction that it would be if it were an AAZ K03.  It's basically a ring with the six appropriate holes.

[zuhandenheit]

Oooohh, that's right. I knew that at one point. I put this project on hold so long that I started forgetting things - I thought I needed to get an adapter plate, but I couldn't see why.

I have a drill press, so I'll see if I can make an adapter plate myself.

[GEE-BEE]

You will need my hose kits also

http://www.thesamba.com/vw/classifieds/detail.php?id=1177342


http://www.thesamba.com/vw/classifieds/detail.php?id=1199730
freebie if you order the engine assy

[Diesel_Zuk]

Oooohh, that's right. I knew that at one point. I put this project on hold so long that I started forgetting things - I thought I needed to get an adapter plate, but I couldn't see why.

I have a drill press, so I'll see if I can make an adapter plate myself.

Ironic, I made the same mistake the other day before doing research, and ordered an aaz manifold. I am in progress of making an adapter as we speak. Here is what I have so far. It is a work in progress, and is just on a piece of scrap steel I had laying around. I will trim it down to exact size once I clean up the inside hole and drill and tap the holes for the turbo:

[libbydiesel]

Hole saws are not cost prohibitive, IMO.

[Diesel_Zuk]

Hole saws are not cost prohibitive, IMO.

Fail, that didn't even cross my mind lol. Well I don't have any that are the right size anyways, and when you are in college and work at a near minimum wage job, many things are cost prohibitive lol.

[Diesel_Zuk]

I will be cleaning it up with a die grinder anyways so I don't really care what the hole looks like.

[zuhandenheit]

Hey Diesel-Zuk - funny that we've got the same problem! I just ordered some steel plate and will try to make an adapter. What's the thickness of yours?

[Diesel_Zuk]

Hey Diesel-Zuk - funny that we've got the same problem! I just ordered some steel plate and will try to make an adapter. What's the thickness of yours?

I'm using 5/16". I just realized I screwed up this first one. one end of the triangle on the turbo will be off the plate. I thought about cutting and adding some by welding, but then it wouldn't be perfectly flat. I will be redoing mine, and going to use a hole saw this time.

[zuhandenheit]

Here's what I'll be using: http://www.ebay.com/itm/1-2-Steel-Flat-Bar-Plate-6-x-8-/300832569261?pt=LH_DefaultDomain_0&hash=item460b04b7ad