Fatmans Ventslo!

[Fatman]

Hey there. Im Stefan and I own a MK3 Vento or jetta (dependant on what part of the world yours from lol). I am from Northern Ireland btw and we do love our VW Diesels here. Ive had it for a year today and I love it! Its a 1.9L diesel and I think the time has come to get a bit of boost in my life. I know very little about diesels and IDI engines in general but I am very keen to learn as I have just bought an AAZ to drop into this thing at Christmas time. So... the car itself!

This is it in the begining:



After a plenty of fiddling, skint knuckles and swearing... it turned into this:





So... the engine build. I have just purchased a 1.9 AAZ engine and I want to put a few nice bolt ons onto it before I drop it in. The plan is to do this at Christmas when i have a months holiday from college so I can concentrate on getting it done.

Engine
1.9 AAZ block (no A/C or Powersteering)
1.9 AAZ head
PD150 intake
Some sort of intercooler
Clutched alternator pulley
K24 turbo
1.6 TD pump with governor mods
EGT gauge and sender
2.5" turbo back system

Now... I need some advice.

With regards to gearbox... should I use the AAZ one or the one from my 1.9 straight diesel?

Also is there any difference between the GTD pump and a normal TD pump? I have been offered a TD pump at decent money.

I have seen people talking about using the inlet from the 1.9 straight diesel on the AAZ. Is this possible? Will it be better than the PD150 intake? Is there any clearance issues with using it?

Any advice and comments on the car are much appreciated

[R.O.R-2.0]

well, the 1Y intake will work, but it will hit the stock turbo and manifold. you will either have to flip the stock manifold, or run a low mounted turbo of some sort. i have a Garrett GT17 vnt turbo on my rabbit (golf on your side of the pond)..

i dont know what intake will be better, or if either one is significantly better than the other.. but i would go for the 1Y intake. i have a intake from an 8v gasser engine on my diesel.. it works much better than the stock intake, thats for sure..

[Fatman]

Got any pics of how your turbo and manifold are mounted up man? I also has an inlet from the 8v digi from a Golf.

[R.O.R-2.0]

you still need a low mounted turbo to run a gasser/1Y intake. only reason i used a gasser intake is to match the oval ports in the 1.6 head. AAZ/1Y has D shaped ports. so a gasser intake would flow like crap on an AAZ head with D ports. my turbo hangs out right next to my passenger side axle.. not up behind the intake manifold..



see what i mean about the turbo being mounted down real low?



the beauty of a VNT turbo, you can run almost any intake manifold..

[MJF]

I am using 1Y intake with AFN exhaust manifold.

[R.O.R-2.0]

thats not a typical setup tho. it looks like it comes more straight out of the head, than out AND up.. doesnt look anything close to a AAZ or 1.6TD manifold setup..

cool setup tho!

[MJF]

Yep, much better than 1,6 or AAZ manifolds.

[R.O.R-2.0]

what kinda car does an AFN come in? surely something across the pond and there is no hope for us over on this side?

[MJF]

It´s ´94-´98 110hp TDI used in all VW/Audi. Same manifold is also used in longitudal 100-130hp PD engines.

[R.O.R-2.0]

i thought we only had like the 1Z/ALH/AHU engines? guess i dont pay enough attention to TDI cars. they just dont turn my crank like the mk1/2 diesels do..

[Fatman]

Hmm interesting setup B.O.R-2.0. How have you got the turbo to mount so low?

Coincidentally I am picking up a PD90 in the coming weeks that has blew a headgasket so a maybe able to borrow a few parts for that... maybe the exhaust manifold. I also have 1.6 and 2.0 gasser engines that I can get parts from too if the need arises.

[R.O.R-2.0]

my turbo is a US spec garrett GT17 vnt.. it comes factory on ALH (2001 till like 2004? someone correct me on this)engines on this side of the pond. turbo and manifold are all one piece. it mounts low like that factory. makes for super easy routing of downpipes too.. the PD 90 might have a decent low mounted vnt turbo. a KKK KP39 will also work, they mount down low too, single piece turbo and mani also..

[Fatman]

Looked into a VNT turbo but they are very expensive here £300 for a second hand one from a junkyard.

You mentioned a reverse mounted exhaust manifold. Is that difficult to do? Is it just a case of flipping the manifold and bolting it on?

[R.O.R-2.0]

flipping the exhaust manifold and turbo are far from easy to do. sure, for someone like me, its easy, but i dont know how mechanical you are. you have to change the oil lines, intake lines, downpipe, grind on the manifold. its not just a simple unbolt the turbo and manifold and flip it. theres a thread detailing the flip on here. below your thread.

and yes, i know, VNT turbos are VERY expensive..

[Fatman]

Just searched for it man. Looks easy enough to do so Ill give it a go

Just bought a K24 Turbo and some GTD injectors. xD