Steel sump turbo return

Hello everyone,

What fitting would i need fot the turbo return on a mk2 tdi steel sump?? (1/2 BSP???)

Thanx Shaun

Have you had any joy shauny?

Na none yet ebo..

I finally got some k04 lines.. oem oil and custom water… but oil feed dosent match the tdi oil filter essay.. was hoping i could chop the banjo off and put my own bit of braid with banjo on? but apparently it's under a lot of pressue and a jubalee wont hold???

As for the oil return wish i got just a standard steel sump and drilled a hole to suit where the pipe flange is… bit of a faff now choping and putting braid between.. not under so much pressue tho???

Then the water lines… lol these custom lines seem to foul either the oil bajo to turbo or the actuator thing…

I'm getting bretty p*ssed of with it all now! everything seems to be a pain in the ass!! even just trying to get some AGU coolant pipes to see if they suit?? Going through paypay resalution sh*t now

Ooo forgot to say the oil return seems to be in the way of the down pipe and the bracket that holds the turbo is usless

Scowered Here, clubgti, vortex, fortude, ed38, google, youtube any other resorce, no info!! as you probably know..

Its been done before but i guess people don't like to give secrets away!! lmfao

Other than that its all hunky dory…

Might take up sewing instead??

Ive got no expierence fella but immagine there must be some way to knock em up. What diamiters it? Could you make it up outta some copper line and use your origenal fittings? Ive not actualy tried the lines ive got but knowing my luck…

Been told i could cut out and replace the flex on my aeb return pipe but the guys not a reliable source so i got a agu one lmao Gonna make my sump this week there isnt much info avalible information on modifying a 8v sump

What did the turbo come off of? I got ko3 off the mk4 aswell guy chucked it in for £20 so thought why not have a spare.

Coolant wise i think your meant to use a laguna top hose and a mk2 8v bottom for rad ill let you know if metal mk4 lines fit.

Same her next time im buying the easiest engine for whatever creation im makeing.
We all love a bitta sewing

Yea i sussed all the parts out to custom make the lines might of been a bit bigger/upgrade?? but it was a little dearer so i went for the OEM stuff thinking it would save me the hassle!! lol I think i might even get rid of these and go down that road in stead??

I've offered my sump up and it looks like if you had the 8v sump.. all you need to do is drill 20mm?? hole in the back right hand side then a couple of 6mm holes tack a couple of studs from the inside gasket on outside, then can use the standard return pipe?? I would change mine but i've welded baffles in already

Not sure what the turbo came off.. but its a k04-023.. did want a k03s but couldn't get one.. kind of the same with the engines.. started as KR conversion!!

Yea i've found bits on the rad houses but its the actual plumbing, as simple as it is i don't know what i'm looking at!! can i use the aeb stuff or agu or custom my own system?? God knows lol.. Yea if you cover that part would be good to hear what you did!

I told mam i'm going to put some better motors in her "Singer" for my next project! haha

Will the vag lines fit if not bolted to the correct locateing points? As a temp mesure ofcourse lol

What sump have you got? Mk3tdi seems a direct swap except you would then need a mk3 return pipe. Also likeing your baffels may need to knock some up when im doing the oil feed.

I was looking for a kr for a while and ended up with a aeb funny how the world turns lmao

Im planning to find my haynes or more proberely bother someone on here lol but at the minute im guessing that i may have to draw myself a picture lmfao

Rubber pipe plan.
Pump - bottom of rad
Top of rad - t piece
Rad breather - expansion bottle
T piece - top engine pipe and expansion bottle
Top engine pipe - heater matrix
Heater matrix - expansion bottle

The metal pipes are a different story im still to look into em i know it uses a oil water cooler but what exactly they do i still have to find out.

Im guessing the breather on servo goes to the passenger side of inlet
But i need to investigate the rest … Lmao

I could get them bolted to turbo apart from the water line.. i'll have to come up with a plan for that.. but the oil feed banjo at fillter essay is at the front on on 1.8t where as on the tdi one its on top.. I like your thinking about mk3 tdi lines… might see if it's easier to make them suit the turbo.. Simple thing's like that i over look!! lol

Yea is a mk3 or mk2 tdi sump think there both the same… Thanx i got the paper templates for the baffles off clubgti.. not sure if there still on there because the chap who had em has been banned… Pretty sure i have them somwhere??…. yep found em! not sure how to add pdf to here but if you pm me your email i can send you them if you like..

Haha yea.. great minds think a like! so do the not so great one's!! lmao

I tried to do that sort of thing fom VAGCAT diagrams.. i did one for the AEB and one for  the AGU weather there right?? lol see if i can find them…..

AEB..
Water pump side - T for waterjaket - engine end junction

Water pump bottom - rad bottom+expansion tank  - rad top - T for turbo - T to expansion - T for water jacket - engine junction

 ?'s
matrix feed, return
 
AGU..
Water pump side - T for turbo+expansion -T for water jacket -  *T to junction A - matrix

Water pump bottom - Rad botom - Rad top - junction A - *T on metal pipe+expansion+engine junction - water jacket+matrix

Because the AEB metal pipe and engine junction was no good for the transverse set up I was trying to compare both systems and come up with my own… main thing to make sure the breather was at the highest point of the system..
Then i realised if i adapt the metal pipe to suit the pump side the AGU set up would work?? and thats where i was at waiting for the bits to see if it would work… Strangest thing, why isn't there any answers to this conundrum!?!?

Also with the water jacket you have to turn it front facing to avoid the front engine mount so the pipe's wont fit any way!! lol

Good call on the servo.. i'd forgot about that.. isn't it a vacum of some sort??…..
just had a goose and seems it's fed from the intake manifold so no need to worry at this stage
Ahh.. i get what you was saying now!! lol

Together we might make it throught this!! lol   

Alright fella not stopped recintly killed my jeep so had to sort octy now both mobile again fitted new kitchen cat died dog ate my home work… cousin came down to show me her new car and rammed the postie off the road my brother came to visit and broke the new sink it never stops lmfao

finialy im back to the golf planning on takeing the agu sump and copying where the return feed is my mate was telling me about converting transits to tdis doing the Same but reckoned you could just seal it and it would be fine without being bolted as the returns are low pressure… Still getting bolted lmao

Im also supprised no ones shareing diagrams for what goes where. Ill pm you my email for the baffels diagram.

On the move so better start paying attencion to what im doing. You had any progress?

F-in hell mate sound like you have had it all going on!! lol

Yea think it would be definetly better bolting the sump return looks quite easy tho as long as its out the way of the downpipe?

Did you recive the emaill??

Haha yea best mate, wouldn't want a lampost to jump out on ya aswell, hehe..

Not much to report, got another set of AGU coolant hoses on the way wich is hopefully in better condition.. I'll let you know if they work also got them turbo lines up for sale which puts me on hold to make custom ones till there sold

Hi mate, recived the AGU lines this morning….. Nope, the solid pipe is no use no matter how i wanggle it about back to the drawing board for that i'm affraid! lol

Aye i did cheers fella look simple enough to knock up see your oil pickup pipe did you swap to 8v to match shallower sump? Dunno if itll fit but im hopeing lmao

With anyjoy because im gonna use the golf unit itll go the other way but ill keep you posted anyhow

Noooooooo lol nothings easy like found a exit hlle on my back diff so the jeeps again doa near had one free last night but it was a ten spline instead of my 24 (fg£&@**+^#) swapped a axel allready killed my engine lift total mission like.

Gotta get the mrs from work ill be back

Yea not to bad i sent mine to get lazer cut, also wanted the flange for the down pipe cutting aswell.. Like i say make cardoard templates to make sure they fit snug

Cheers mate would be good to fathom it out?? i must surely have enough ppe now to come up with something and just do away with the solid pipe, or only use parts of it??

Haha it never rains but it pours ay ebo you must feel like pulling your har out!! lol

ebo said

Im also supprised no ones shareing diagrams for what goes where.

A couple of good threads on another site for what goes where… Clicky , Clicky

Richard asks alot of good questions that i've bumed  info from Cheers mate if you ever read this!!
But with it all relating to AGU it is different  but the same concept?? i suppose? lol

Alright Shaun,

I've just done all my turbo lines for an AEB block and steel sump. I've just used the agu feeds, with alot of cutting and jubilee clips. Its abit of a bodge but seemed the only way. Hopefully the clips will be strong enough to hold!!

I can try and get a pic up for you if you want mate. For the steel sump, I've welded a boss onto it for the return and joined using some braided hose.

Cheers

Alright mate..

I've gone with a K04 turbo so needed the lines to suit that.. but as you say they need adapting and i just spent a chunk of money on these lines so don't facy chopping them up, lol.. I can custom make some! i've priced all the bit's and by the time i'd baught banjo bolts etc from audi it will work out cheaper than OEM hahaha love going backwards    got to get rid of these first now!

Yea i made a boo boo getting a tdi sump would of been much easier to put a boss in a 8v sump..