1.9 AAZ upgrade for 92 Jetta TD

[ilikevwdiesel]

Anyone have any thoughts on this:

I am installing a 1.9 AAZ motor into a 92 Jetta TD. I plan to use just the AAZ longblock, timing belt and intermediate shaft pulley. Everything else will be 1.6 TD. Here's what I am wondering...

What is the best solution for making the timing cover fit properly?

What do I set the injection pump timing at? 1mm?

Thanks  

[Quantum TD]

I don't think you need to do anything to the timing cover. I may be wrong, but as long as you're putting an AAZ from a MK3 into a MK2, you should be able to use the stock AAZ timing cover.

Timing according to Bentley should be 0.80 +/- 0.02 mm. That's what I set my dad's AAZ in his Vanagon to. It purrs and has plenty of gusto.

But I think most of the Canadians here push is to 1.00 mm.

[ilikevwdiesel]

I don't think you need to do anything to the timing cover. I may be wrong, but as long as you're putting an AAZ from a MK3 into a MK2, you should be able to use the stock AAZ timing cover.

Timing according to Bentley should be 0.80 +/- 0.02 mm. That's what I set my dad's AAZ in his Vanagon to. It purrs and has plenty of gusto.

But I think most of the Canadians here push is to 1.00 mm.

I don't have the AAZ cover set, was hoping to be able to mod the 1.6 to fit but after looking at it more closely, I don't think it's possible. I'll probably have to find one from another AAZ motor somplace. I pulled this motor from a 92 Jetta in Montreal last week. It has the turbo from the original 1.6TD, but it has an injection pump with an adjustable timing belt gear. Does anyone know when VW started putting adjustable gears on AAZ injection pumps? What I want to do is can the timing belt/injection pump setup that's on there now and replace it with the 1.6 TD system from the car the motor is going into.

[jtanguay]

the 1.9 was designed to run at .8 mm timing for the extra torque and emissions requirements.

[ilikevwdiesel]

the 1.9 was designed to run at .8 mm timing for the extra torque and emissions requirements.

ok so set the 1.6 TD pump at .80 then ja? I will not be using the stock AAZ pump. sorry about the ? confusion  :oops:

[Giles@PerformanceDiesel]

hey
you should set you pump timing to .95mm much better.

why are you not using the AAZ pump? you won't be able to use
your 1.6L pump because the mounting bracket is the wrong size
unless you change that one too.

the fueling curve is all wrong with the 1.6L pump too.
if you have the 1.9L pump use that .

1997 was the year for the split two piece timing gear.

Giles

[Vincent Waldon]

But I think most of the Canadians here push is to 1.00 mm.

I've been trying 1.00 on my AAZ, eh, and  it's like probably like too much, eh, and I'll be backing it off to 0.95 as soon as the snow melts.

Eh ?!   ;-)

All kidding aside... at least on my pump I'm noticing more rattle than I would like (particularly with the cold start knob out) and a bit less low-end torque than my 1.6 used to have up the same parkaide ramp.  When I move it to 0.95 I'll report back, but if anyone asks me right now I'd agree with Uncle Giles that 1.00 is probably too much for an AAZ.

[burnt_servo]

due to the different fuel curve than a 1.6 , i'm willing to bet that a   aaz  at .8mm  will pop the injectors at the same dynamic timing spot  as a 1.6 set at 1mm ... assuming stock injector pop presures .

[ilikevwdiesel]

hey
you should set you pump timing to .95mm much better.

why are you not using the AAZ pump? you won't be able to use
your 1.6L pump because the mounting bracket is the wrong size
unless you change that one too.

the fueling curve is all wrong with the 1.6L pump too.
if you have the 1.9L pump use that .

1997 was the year for the split two piece timing gear.

Giles

Excellency! Thanks for your input. The reason I don't want to use the 1.9 pump is because it leaks fuel at the throttle shaft, and I don't have the technical skill to replace the o ring and the throttle bushing. I am installing this motor in a 92 Jetta, but have decided to pull it back out and just put in a decent 1.6 TD that I have as well. That way everything will be factory and I won't have to shell out the cash to get the pump redone. I'll just hold onto this 1.9 for some other project when I can afford to get the pump serviced, in the meantime I have to find a timing cover for it too. One more thing: does this motor being an 97 or newer suffer from the crank pulley problem? Thanks for everyone's input I appreciate it.

[burn_your_money]

It will still have the crank problem, well the potnential for it anyways.

I have a timing cover for $5.