AAZ Turbocharger: Golf 2 1.6 TD Installation Guide

I'm new here, and first of all, I want to say that this is a beautiful and informative website.

Now, to my question: I have a Golf 2 1.6L TD (I can't recall the exact engine code right now). I increased the original boost pressure to approximately 1 bar and drove it for about 20,000 km. Now, the turbocharger completely failed under full load.

Does the AAZ turbocharger fit onto my Golf without any problems, or do I need to change anything else?

Hello, it should fit, possibly with a replacement of the bend.
Why don't you use the turbocharger from the JX?

I don't know much about it, so what advantages would I get from using JX?
That's the same one as in my Golf.
I'm looking for one that can handle the boost pressure without any problems. The one from the 1.6L engine is supposed to be rated up to about 1 bar, while the one from the AAZ 1.9L engine is supposed to be rated up to about 1.2 bar?!
Am I right about this?

Best regards, Christian.

Hi, so far as I understand, everyone wants to install the turbocharger from the JX engine onto the AAZ engine in their VW Bus (T3 Type 2). Maybe someone knows why, but I think it's because the turbocharger builds up more boost pressure.

As far as I remember, the AAZ engine runs with a boost pressure of 0.4 bar and has a very small turbocharger.
It's better to go back to a part from JR. I experimented a lot with mine back then. It easily handled 1 bar. It only broke when I got overconfident and completely closed the wastegate, which resulted in about 1.7 bar. It ran like the devil, but unfortunately, not for very long.

If I understand correctly, everyone who converted to the AAZ engine is now switching back to the JX engine, but I thought those were essentially the same engine as the one in the JR?

@Felix: I had the JR loader installed, and it exploded on me (literally) at 1.0 bar.

Can anyone tell me definitively whether the AAZ turbocharger will fit my Golf without any problems?

Thank you, and best regards, Christian.

Okay.

If JX Busler installs an AAZ engine, they will use almost ALL of the related components.

JX ESP, JX TURBo, etc...

A colleague of mine has a JX with an external oil cooler and he's pushing up to 1.2 bar into it - and it works, at least the engine/turbo doesn't want to break (so he can finally install a TDI ).

m;

Thanks for the reply. I'll see what I can do. I currently have a new (used) JR loader installed, so I'll try increasing the speed and hope it holds up!

Best regards, Christian.

The AAZ engine's turbocharger boost pressure is (measured) between 0.6 and 0.65 bar. I drove for 80,000 km with the boost pressure at 1 bar and didn't have any problems with the turbocharger. The turbocharger wasn't defective; I had an accident.
He once followed me around, but back then it also had more than 1 bar of pressure.
The 1.6-liter engine requires approximately 20% less air than an AAZ engine. Consequently, the turbocharger won't need to reach the same RPM as it did in my AAZ to build up the same boost pressure.
I wouldn't drive with more than 1 bar of boost anyway, and I'm optimistic that it will hold up with the AAZ turbocharger (KKK).
I had my turbocharger repaired by STK (www.turbocharger.de). It was cheaper than Motair, and I was satisfied with the result. They might be able to install different bearings in your old turbocharger as well. It's worth asking them!

Enjoy your meal!

The AAZ turbocharger that fits on the JR engine should also fit on the JX engine and the rest of the 1.6-liter turbo engines.
But:
There are various turbochargers available at AAZ, which differ, for example, in the diameter of the...
Sealing inlet and outlet, or the connection to the manifold, via the flange.
The AAZ turbochargers I've had experience with so far have smaller turbine housings.
(Using a Garrett T2 instead of a T3) as the 1.6-liter turbochargers, meaning they spool up earlier, but...
at high speeds, it tends to be "too" much, and it seems that it reaches its peak in the range of 4000-5000.
Exhaust stream being braked too strongly.
I installed an AAZ turbocharger on my Golf 2 TD/JR engine, with the VW part number...
028 145 703 B was built because I prefer an engine that performs better from lower RPMs.
The 703 B fits onto the manifold, and the diameter of the compressor outlet is...
"The same size as the turbocharger from my previous 1.6-liter engine (VW part number=?, already sold)."
The diameter of the entrance is smaller, so you have to find a way around it.
It gets more complicated with the oil return line, as the one from the 1.6-liter engine doesn't fit.
A pipe comes out of the 703 B fitting, with an M 18 * 1.5 external thread at the bottom, onto which you can...
Screw on a 90-degree angled hose fitting; the hose is 1/2" in diameter and connects to a 1.6mm pipe.
remove the hose and weld on a 1/2" hose fitting (originally 15 mm).
Connect the lower part and use a suitable hose to connect it to the 90-degree elbow; it's ready.
You can find hoses at a hydraulics shop or at a tuning/accessories store.
for example, the 90-degree arc from racimex;
If the end nut of the arch only screws onto the pipe by 1-2 threads.
"Then, you have to unscrew it. The sealant inside the pipe is at 60 degrees, although the usual temperature is..."
Apparently, it's 24° today, and that's what the pipe should also be.
The turbo can also produce up to 1.4 bar (which I find too much) and provides good response at low RPMs.
significantly improved.
Okay, and one more thing: The turbos from the SB/RA engines also have the correct size.
are water-cooled.

Hi, Jockel.

These were the answers I was looking for, thank you so much again!

Best regards, Christian.