AAZ Turbodiesel swap into '86 Vanagon Syncro

[Zeitgeist 13]

Something sure doesn't sound right. I've built dozens of VAG diesels up from new bottom ends etc., and never had one produce excess blowby after the initial start up and the break in period. Hate to say it, but perhaps a leakdown test is in order.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[Gizmoman]

I sympathize with you on the blow-by. I know you know, but It's been written that the engine needs to immediately get pushed hard with new rings or you get polished bores.
What "procedure" did you use during your initial run?

I'm still fiddling with wiring and the coolant pipes but should be running soon. Working this thing hard after all the work, money and mods is going to be tough for me to do right out of the chute.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale).

[johnnygreenham]

[Syncroincity]

I certainly didn't baby it, I always tried to vary the speed, accel & decel a lot. It did idle an awful lot, though, particularly taking it to work where I sit in traffic for an hour.

If I blew the break-in, what am I looking at, re-hone and new rings?
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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[Zeitgeist 13]

I always broke in these engines the same as any other. Get the engine speed up and vary the RPMs so that it doesn't sit at one speed for too long. 500 miles should be more than sufficient for a thorough break in period.
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[lloydy]

can't remember if i posted these pics before?.. i had the same idea with the oil seperator, but did it slightly differently
oil seperator from a bmw x5

[/quote].banjo fitting and hose so oil seperator drains to block using the block oil return tapping

and one way valve to stop the block venting back up the breather drain

the banjo fitted

seperator fitted with silicone hoses

i also fitted the VW block filter, seen here next to the standard type

[/quote]
the one way valve fits between the drain on the unit and the banjo on the block, the one way valve is not meant to be needed if your returning below the sump oil level..
I trial fitted this set up with clear hose just to see how clear the breather set up to the inlet was, as you can see it does a pretty good job

and after

i hope you get to the bottom of this issue soon, I'm having a AFN tdi built up now with oversize pistons, as i've bent a rod in my current one, we should have a smoke off see who wins
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Syncroincity]

Heh, you're on. I'll get some video this weekend.

I've got several issues going on at the same time that have some cause/effect overlap, I just have to tackle things one at a time.
Job one is getting the oil contained so I can drive the damn van more than a few miles without having a Valdez moment.
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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[Gizmoman]

[johnnygreenham]

Thanks for the pictures lloydy, I'm glad your oil separator system works for you. I was a little confused about two things though. Looks like you drain the oil from the separator back into the block where an AAZ original turbo used to drain back. You have a one way valve in that line. Not sure how it open unless you have pressure to open it?

You also return the vapor from the oil separator back to the sump below oil level..........not sure how the system works if your vent/breather gasses form your crank case are just directed straight back into your crank case.
Maybe thats where you get your pressure to open the check valve in oil return.

If you could explain those two brain puzzlers i'd appreciate it.

johnny
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1982 Diesel 1.9TD AAZ

[lloydy]

Hi, yes the oil from the seperator returns to the old oil return from turbo tapping. The one way valve is very weak in the direction it needs to flow. It is actually a Mann part that is a option for their provent, so is designed for the job. You can literally just breathe in the end and it opens..
This connection is above the oil level in sump so needs the one way valve.. Nothing returns below oil level? The fitting you can see on the sump, is from me starting to mock up the oil return for the turbo. (I have a tdi, turbo is in slightly different location)
The breather set up still connects to the air inlet as per factory (just has the oil seperator fitted in line)
Hope that clears up any confusion?
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16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Syncroincity]

Ah, yes, the infamous Mann $50 check valve. Electric pump and timer board will cost less... and I'm still not convinced it won't be held closed by crankcase pressure, above OR below the fill line.
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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[johnnygreenham]

[Syncroincity]

Well, ski season's about done, so here we are again.

My first official act of 2014 was to rebuild the turbocharger.

Got the Garrett T2 rebuild kit from Ebay for $70;

http://www.ebay.com/itm/380390903018?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

A few parts are not quite right; the hot side clamp ring halves are set up for 4 bolts, mine has 6 so I had to drill a couple of extra holes, no big deal. Also the compressor housing o-ring is too big... I just re-used the old one, it was in good shape.
Everything else is spot-on, and the kit comes with the upgraded 360-degree thrust bearing.

I had the turbo out & apart to clock it last year, so removal and disassembly was a breeze this time.

This video was helpful to see what I was getting into;


Link



Link

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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[tortuga480]

Nice job on the turbo.
How is your (2nd?) intercooler set up holding up?
Do you have EGT measurements with and without it?

[Syncroincity]

Thanks. Longevity remains to be seen; I tried to index everything during teardown, hope the balance isn't too far out.

WAIC works great, even without a reservoir... enough hose to hold over 2 gallons of coolant. EGTs never get above 1100 maxed. No data for un-cooled operation.

I have to pull a rear axle due to vibes, I think the right side may be contacting the stub axle... might need to trim it down some. Now if I could just have a day off without pouring rain or freezing temps.
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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[tortuga480]

[[email protected]]

I have a 1.9 L NA in my 83 tin top, I took it into a shop belonging to a guy I have known for several years. I like checking things like numbers, I found that I had a 1.6 L IP on the 1.9 L diesel. I took it to a shop to have a new belt and have the IP adjusted as the vanagon was knocking until it got warmed up. I went out today and checked the valve timing, I noticed that the IP was one knotch off?? The bus runs great??? I want to install the timing belt cover, none is there..... I bought a back cover - steel and a close to matching plastic cover. I wondering whether the addition of the steel cover will impact the injection pump timing???? Open for any suggestions. [email protected] No sereal numbers on the block????

[Syncroincity]

[Gizmoman]

Bummer on your turbo rebuild. I finally gave in on my "rebuilt" k-14 puking oil and went to a Holset 200 ($620). A fair amount of re-work was required but WOW, it's like a different engine. Let me know if you need details.

I think the k-14 would be fine at 8-10 PSI but I was pushing it to 15-18 and it still didn't produce enough air to feed the Giles IP fueling. My cruising pressure was 12-15, now it's around 8.
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82 Vanagon Westy - AAZ 1.9 TD, HE200 Holset, WAIC, 27.75 dia tires, Electric power steering, 5-speed AAP w/.078 5th
Oversize spare carrier - stock location (no longer for sale).

[Syncroincity]

Gizmo, Yeah I've been considering the Holset; along with one of the VNTs I have laying in a pile... everything is going to require re-doing the exhaust, intake and adapting the manifold; something I'm not ready to do quite yet.
I'm going to see if these guys can hot-rod this Garrett T2 a little, they seem to be pretty conversant with hybrid Garrett setups. I'm also hoping to avoid having to use the TDI-type adapter left engine mount.
I was running about 17psi max boost, it seemed pretty willing at that level, as I said earlier, 1100 EGT sustained, maybe 1250 going up a good long hill. It spools up immediately off idle... the turbine wheel is the size of a quarter. Good level of boost for the van, not a rocket, but gets out of it's own way, climbs any hill without complaint or downshifting.


I was kicking around the idea a manual VNT controller; something like a boat throttle quadrant mounted down by the e-brake lever on the seat pedestal that I could adjust the vanes between power and cruise settings, and also be able to work back & forth occasionally to keep the carbon build-up down.
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'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=