Old 1.9l WBX engine/trans:
1.9l TDI 1Z Engine build:
Head mated, centering studs removed and head studs torqued to spec. Long block complete.
A new elegant solution for the turbo oil supply line: Instead of the stock OE rigid steel pipe KermaTDI came up with this simple and sweet flexible stainless high press hose with the correct fittings on each end for the AHU/1Z with oil feed coming off the oil filter flange and not the cyl head (early 1Z).
The stock oil supply pipe is notorious for developing cracks resulting in deal breaking end of trip results with high pressure oil leaking EVERYWHERE. The veritable Achilles heal of the AHU/1Z engine.
1) Ideal probe site is identified and then checked with turbo installed on eng to verify clearances.
Test incisions made to assess suitability
5) Mirror image cut with plenty of material for tapping and just enough room on the side.
Clutched up! This is our STD heavy duty hybrid G60/WBX clutch set up we use now on our Vanagon TDI conversions: Lightened G60 flywheel (228mm), WBX disc (228mm), G60 pressure plate. This set up can hold over 320ft/lbs torque and we've yet to find their slipping point even on our biggest builds (stage VI). And on top of all that with this flywheel you can still remove the oil pan without removing the trans which isn't possible with the stock AHU/1Z flywheel.
Another view of our hybrid clutch set up as well as the new flexible SS turbo oil supply line.
Build tag from tranny shop.
Installed TDI engine with coolant system complete, fuel system complete, power steering system complete, intercooler system complete, air intake system complete and wiring nearly complete.
***All pics and conversion work done by TDIpowered.