1.9 AAZ turbo advice needed

[Stacks81]

Recently installed a new turbo on the 1.9aaz in my 82 vanagon. Have a couple oil leaks the need to be addressed and was wondering if clocking the turbo and adjusting the drain pipe is something I should do. Please let me know if anyone has done this or if clocking is something I shouldn’t do..

Thank you.

[?Waldo?]

Definitely clock the center section better.

Also, add the one-way pulley to the alternator. The solid alternator pulley is likely to cause the crankshaft sprocket to fail which results in engine death. It is a well-known issue with the AAZ serp belt setup.

IDParts sells both the tool that lets you swap the pulley without pulling the alt (https://www.idparts.com/metalnerd-serrated-alternator-pulley-bit-set-a4a5-mn3400-p-564.html) and also the one way pulley (https://www.idparts.com/alternator-pulley-a4a5mk6ckra-022903119c-535001210-p-1118.html). $60 plus shipping is cheap IMO to reduce the chance of catastrophic engine failure.

Clocking the turbo and allowing it to drain better might reduce the leaks. They may also be a result of oil mist from the crankcase entering the intake (which is normal). I personally prefer to run the drain to the oil pan rather than the block as it gives better drop for the drain line which operates on gravity alone.

[11BC2]

The oil return pipe/hose is kinked.

[Stacks81]

Right on thanks!!

[Gnarlodious]

My AAZ has 1.9TD embossed under the exhaust manifold. Maybe someone can clarify, but these parts don't look like AAZ.
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[Stacks81]

So I recently made a new drain line for my turbo.
Bottom of the turbo 16mmx1.5 to 6an adaptor to 6an 90degree fitting
Ptfe hose to the banjo fitting into the block.
No leaks form the top or bottom of the turbo
Have some excessive oil coming out of the exhaust. Recently just changed the oil 5 quarts 15w40 and installed an oil catch can for blow by. Reenforced vinyl tubing 1/2 ID to 3/8 ID to catch can exit hose from catch can attached to intake tube. No oil in the hose lines.

Upon further inspection I found a hole in the top of the engine. Looks as though this is the old dip stick hole. It open looks to be misting oil out of it any way I could/should plug this? If so with what?

I’m thinking I have a little excessive blow by. I know it’s an old engine and a diesel just trying to figure it all out.. thank you!

[narendra.vw]

Let me share my experience on 1.9 eTDI 50* tilt Turbo.

after a year later many km on the engine the exhaust started to spill oil. after doing some research & advise I started with drainpipe. mine is at the bottom of oil pan(crankcase) as TD. some said it should be at the top of oil pan. some say due to tilt of the engine, next, breather valve, oil viscosity. List goes on.

I just went for a sealed 'OE' Turbo. problem solved..
My direction will be go to scrapyard, find a low mileage engine & use its Turbo.

[Gnarlodious]

I would strongly recommend a 2½” exhaust system with a non-restrictive muffler. It solved all my problems with oil blowing out and leaking. In addition to other problems I didn’t even suspect were caused by insufficient breathing.
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Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[Stacks81]

[Gnarlodious]

You should read my exhaust build post:
https://www.thesamba.com/vw/forum/viewtopic.php?t=728825
…paying attention especially to the trouble I had at lower elevation, since you are in New Jersey.
_________________
Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[Stacks81]

Wow that is a beautiful exhaust!

[Stacks81]

Wow that is a beautiful exhaust!

[Witless Joe]

[?Waldo?]

The ratchetting pulley and the solid pulley are typically interchangeable. I ran into an aftermarket alt a few years ago that had the solid pulley and the shaft of the alt just beyond the threads got winder and interfered with the clutched pulley. My solution was to spin the alt using a drill and grind the shaft narrower where it interfered, using a dremel. YMMV.

[Witless Joe]

[Witless Joe]

So on further investigation, I think the pulley in that link to the ID Parts store is the wrong one.

This new pulley is about 61 mm in O.D., while the original solid pulley is only about 54 mm in O.D.

This post explains that there were actually two different sized clutched pulleys for VW TDIs, and I think I ended up buying the one that is too big: http://vwdiesel.net/forum/index.php/topic,24517.0.html

I think I need Part# 028903119AA, which is only 55.5 mm O.D.

Before I hack up my alternator shaft, I am going to try to buy and install the smaller pulley, and report back.

[Witless Joe]

[?Waldo?]

Thanks for adding that info Witless Joe. You are correct about the size difference. In looking into it further, some people have used the ALH pulley on the Mk3 alternators without issue and others have the issue you described.

Another INA # for the correct part for the Mk3 alts is 5350001100. It is actually available at SummitRacing for $37. https://www.summitracing.com/parts/ife-ea0001

[Zephyr_shreds]

Which clutched pulley should I get for the 1.9 1y

[?Waldo?]

The 1Y is a Mk3. I posted the part number for the correct clutched pulley in the post immediately before yours.