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vintagemotion
Samba Member
Joined: December 13, 2009
Posts: 73
Location: Kleve Germany; Atlanta Georgia
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 Posted: Wed Oct 13, 2010 6:59 am Post subject: TDI conversion AHU Turbo adapter sketch/ dimensions |
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After a couple months driving without Turbo I want to tackle my last AHU conversion challenge - turbo positioning.
Based on the forums recommendation I decided to turn the original AHU turbo upwards with an AAZ exhaust manifold instead of using the European OEM VW JX setup. .
I have all parts except the adapter. Here my question:
1. Using an adapter requires 6 bolts to fasten the turbo. Does it really take special stretch bolts or would a conventional 8.8 or 10.9 strength metric bolt work? Any experience / recommendations?
2. This forum has pictures of adapters made from steel or aluminum. In my opinion using aluminum would be an issue because of the different thermal elongation (unless stretch bolts are used?). Any experience / recommendations on material?
3. Does anyone have a sketch for an adapter with dimension or even better a source where I can buy one already made to fit.
4.My OEM Diesel Muffler has a 1.5” connection. Any recommendation on a 2” or 2.5” Muffler from another car that would fit reasonably well.
_________________
82 orange Diesel Westy
AHU conversion (mechanical with stock JX pump)
5 Speed ASS
CLK Wheels 215/70/16 |
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westyventures
Samba Member
Joined: December 29, 2004
Posts: 2306
Location: Oregon Outback
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| Posted: Wed Oct 13, 2010 7:45 am Post subject: Re: TDI conversion AHU Turbo adapter sketch/ dimensions |
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| vintagemotion wrote: |
After a couple months driving without Turbo I want to tackle my last AHU conversion challenge - turbo positioning.
Based on the forums recommendation I decided to turn the original AHU turbo upwards with an AAZ exhaust manifold instead of using the European OEM VW JX setup. .
I have all parts except the adapter. Here my question:
1. Using an adapter requires 6 bolts to fasten the turbo. Does it really take special stretch bolts or would a conventional 8.8 or 10.9 strength metric bolt work? Any experience / recommendations?
2. This forum has pictures of adapters made from steel or aluminum. In my opinion using aluminum would be an issue because of the different thermal elongation (unless stretch bolts are used?). Any experience / recommendations on material?
3. Does anyone have a sketch for an adapter with dimension or even better a source where I can buy one already made to fit.
4.My OEM Diesel Muffler has a 1.5” connection. Any recommendation on a 2” or 2.5” Muffler from another car that would fit reasonably well. |
I'll answer, since I'm the originator of the concept. I use only grade 10.9 or 12.9 metric bolts. The adaptor is 1/2" thick steel, 3" diameter, with a 1.375" hole. Note that the manifold bolt pattern is slightly different than the turbo pattern. The part bolts to the manifold with the original turbo bolts. The turbo mounts to the adaptor using one stud and two through-bolts, installed into the adaptor side first. No gasket is necessary as long as you have sanded the adaptor on a metal belt sander or equivalent. The two turbo bolt heads may require a small grind on one side to fit the recesses of the manifold. Of course, you also need to re-clock the turbo for proper drainage and orientation. I've done a bunch of them this way and works great!
Muffler - I always use 2.5" SS tubing and Performaster SS glasspacks for the conversions. These have a nice quiet tone and are free-flowing:
http://www.stainless-specialties.com/products2a.htm
Also considering adding a short flex near the turbo and a Magnaflow diesel catalyst to keep it clean. You can see pics on my site of the setup.
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vintagemotion
Samba Member
Joined: December 13, 2009
Posts: 73
Location: Kleve Germany; Atlanta Georgia
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| Posted: Wed Oct 13, 2010 9:03 am Post subject: Re: TDI conversion AHU Turbo adapter sketch/ dimensions |
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| westyventures wrote: |
| vintagemotion wrote: |
After a couple months driving without Turbo I want to tackle my last AHU conversion challenge - turbo positioning.
Based on the forums recommendation I decided to turn the original AHU turbo upwards with an AAZ exhaust manifold instead of using the European OEM VW JX setup. .
I have all parts except the adapter. Here my question:
1. Using an adapter requires 6 bolts to fasten the turbo. Does it really take special stretch bolts or would a conventional 8.8 or 10.9 strength metric bolt work? Any experience / recommendations?
2. This forum has pictures of adapters made from steel or aluminum. In my opinion using aluminum would be an issue because of the different thermal elongation (unless stretch bolts are used?). Any experience / recommendations on material?
3. Does anyone have a sketch for an adapter with dimension or even better a source where I can buy one already made to fit.
4.My OEM Diesel Muffler has a 1.5” connection. Any recommendation on a 2” or 2.5” Muffler from another car that would fit reasonably well. |
I'll answer, since I'm the originator of the concept. I use only grade 10.9 or 12.9 metric bolts. The adaptor is 1/2" thick steel, 3" diameter, with a 1.375" hole. Note that the manifold bolt pattern is slightly different than the turbo pattern. The part bolts to the manifold with the original turbo bolts. The turbo mounts to the adaptor using one stud and two through-bolts, installed into the adaptor side first. No gasket is necessary as long as you have sanded the adaptor on a metal belt sander or equivalent. The two turbo bolt heads may require a small grind on one side to fit the recesses of the manifold. Of course, you also need to re-clock the turbo for proper drainage and orientation. I've done a bunch of them this way and works great!
Muffler - I always use 2.5" SS tubing and Performaster SS glasspacks for the conversions. These have a nice quiet tone and are free-flowing:
http://www.stainless-specialties.com/products2a.htm
Also considering adding a short flex near the turbo and a Magnaflow diesel catalyst to keep it clean. You can see pics on my site of the setup.
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Thanks for the details and sharing your idea with us. This is a very clean solution!! I like it much better than the OEM JX setup. VW should have come up with that!
Can I buy adapters and fabricated down pipes from you?
The flex joint would help to reduce stresses and will change the dynamics (NVH) of the exhaust system. Exhaust flex joints happens to be what our company manufactures for OEM’s like GM, Mercedes etc.. I’m planning to use an exhaust decoupler which is a more complex flex-joint designed with additional damping cushions. This is particular beneficial for diesel applications.
_________________
82 orange Diesel Westy
AHU conversion (mechanical with stock JX pump)
5 Speed ASS
CLK Wheels 215/70/16 |
|
| Back to top |
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westyventures
Samba Member
Joined: December 29, 2004
Posts: 2306
Location: Oregon Outback
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| Posted: Wed Oct 13, 2010 9:09 am Post subject: Re: TDI conversion AHU Turbo adapter sketch/ dimensions |
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| vintagemotion wrote: |
Can I buy adapters and fabricated down pipes from you?
The flex joint would help to reduce stresses and will change the dynamics (NVH) of the exhaust system. Exhaust flex joints happens to be what our company manufactures for OEM’s like GM, Mercedes etc.. I’m planning to use an exhaust decoupler which is a more complex flex-joint designed with additional damping cushions. This is particular beneficial for diesel applications. |
At the moment I can only share the ideas and details - just too overwhelmed with backlogged work. I make each adaptor and headpipe as I build a conversion, so don't have these available as parts for sale. |
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vintagemotion
Samba Member
Joined: December 13, 2009
Posts: 73
Location: Kleve Germany; Atlanta Georgia
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| Posted: Wed Oct 13, 2010 9:54 am Post subject: Re: TDI conversion AHU Turbo adapter sketch/ dimensions |
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| westyventures wrote: |
| vintagemotion wrote: |
Can I buy adapters and fabricated down pipes from you?
The flex joint would help to reduce stresses and will change the dynamics (NVH) of the exhaust system. Exhaust flex joints happens to be what our company manufactures for OEM’s like GM, Mercedes etc.. I’m planning to use an exhaust decoupler which is a more complex flex-joint designed with additional damping cushions. This is particular beneficial for diesel applications. |
At the moment I can only share the ideas and details - just too overwhelmed with backlogged work. I make each adaptor and headpipe as I build a conversion, so don't have these available as parts for sale. |
Understood and I do not want to delay my M-TDI pump from you 
Thanks for your input!
_________________
82 orange Diesel Westy
AHU conversion (mechanical with stock JX pump)
5 Speed ASS
CLK Wheels 215/70/16 |
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outwesty
Samba Member
Joined: June 06, 2006
Posts: 1074
Location: Tahoe City
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| Posted: Wed Oct 13, 2010 5:09 pm Post subject: |
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| I am using the same adapter as Karl has shown above. I used regular grade 8 bolts from NAPA and all 3 snapped off after about 12,000 miles of use. Luckily we were near anchorage and were able to have a machine shop drill them out. I ordered the correct original bolts with the weird 12 pt head and I have not had an issue since. I would use the original bolts or stronger. |
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vintagemotion
Samba Member
Joined: December 13, 2009
Posts: 73
Location: Kleve Germany; Atlanta Georgia
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| Posted: Fri Dec 31, 2010 7:28 am Post subject: Oil drain and Turbo routing AHU conversion |
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I found this picture of an AAZ motor. The AAZ uses the turbo above manifold originally. Can the oild drain and turbo air setup be used with an AHU turbo? I have the AAZ intake and exhaust manifold. I also have the N90837101 screw in adapter for the block. (yes I'm aware of the potential issues with "not draining into the pan").
Does anyone have the Part number for the AAZ oil drain and the AAZ rubber hose that connects the turbo and intake? 
_________________
82 orange Diesel Westy
AHU conversion (mechanical with stock JX pump)
5 Speed ASS
CLK Wheels 215/70/16 |
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| Back to top |
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fairweather
Samba Member
Joined: August 26, 2007
Posts: 663
Location: Aspen, CO
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