Vacuum Nozzle 1Z - Incorrect U-Washers?

Hi.

As you can see here http://web.utanet.at/langzaur/1Z_Ansaugbruecke.jpg, in the upper right corner, LZ has small washers under the 6 screws of the intake manifold.

However, document 129-40 specifies dimensions of 8.1 x 24 x 1.5, and I also received those large plates with a diameter of 24 mm.

Are those really the big ones? Do they even fit (I don't have time to check right now).

m;

ok,

Since no one can help me, I'll just take everything apart this weekend and see if it fits.

It's probably going to be a huge mess after 170,000 km.

m;

Hi Martin,

Okay, I can rule out that a 24mm diameter will fit. Please compare the pictures of the intake side of the head, and then take measurements to see if there's enough space for a washer with a 12mm radius from the center of the thread (M8 thread has a core diameter of 6.4mm). It's unlikely to fit without already being positioned in the intake path.

Best regards, Robert.

Okay, I guess I'll start by discreetly contacting VW to inquire about the appropriate parts, and if they happen to have 24mm options available, I'll definitely consider ordering them!

I was surprised when I received the frying pans, but the order number was correct.

What a mess... You can't rely on anything anymore.

I'm still going to remove the crimp, even though I have new screws.

m;

Hi Martin,

"So, I reused the screws and washers. I don't see any reason to install new parts; 25 Nm isn't a lot. I even reused the nuts on the exhaust manifold that connect to the EGR system after cleaning and removing any rust."
Have fun cleaning the chimney! X

Best regards,
Robert.

PS: Could you check how many screws are used to attach the turbocharger to the exhaust manifold? It's very easy to see from above when the intake manifold is removed. In my case, only two (Torx) screw heads are visible from above, and the third hole in the turbocharger's inlet flange is open.

Sure, I will.

My exhaust pipe is not original anymore.

Ich hatte ein klapperndes Flexrohr und hab im Anflug von Geldvernichtung bei VW das Flexrohr und damit auch den Kat neu machen lassen ... Cough...

Hopefully, they used the correct number of screws.

m;;

I just checked the coverage area (AFN coverage).

The suction nozzle has quite prominent ridges for the screws, maybe the washers will fit after all...

m;

http://www.luxus-wg.de/~martin/auto_bilder/AnsaugTeile.jpg

Okay, I've uploaded a picture of the turbo flange with the empty screw hole http://web.utanet.at/langzaur/1Z_Turboflansch.jpg. Maybe someone has an opinion? I'm missing the mounting point for the third screw. Considering that the entire exhaust system, all the way to the MSD, is attached to it.

Best regards, Robert.

According to the file, that is correct.

The 1Z engine has only 2 hex screws, while the AAZ and AFN engines have 3.

What on earth were they thinking at VW?!

m;

SO.

Since I had already fixed the engine (see here: https://community.dieselschrauber.org/en/viewtopic.php?t=7128)), I could browse some AKTE websites while waiting.

I received 24mm O-rings from VW for the intake manifold (IM).

They don't fit at all because they are much too large. Also, the original parts have screws that are already pressed into the washers (so that the washers don't extend over the threads and can't be sold loose).

So, I started looking at other TDIs... and guess what: with the Passat model change from 3A to 3B, the AHU engine suddenly got 26-inch windshields instead of 24-inch ones (???)

In addition, the AGR (Automatic Geographic Registration) system in the G4 uses a combination of a screw and a washer, and it also uses the M8x45 size.

Okay, I just have to hold on for one more day, then on Monday I'm going to cause a "little people's uprising" at VW to see what kind of "crap" they're trying to sell me (no, I'll be polite, because they're always friendly to me - honestly!).

Here's the problem, in vivid detail:
http://www.luxus-wg.de/~martin/auto_bilder/Ansaug_U_scheiben.jpg

m;