1.9TD tuning

[Maarten]

Since there is a lot of 1.9TD AAZ info scattered over the board I thought it was a good idea to post them in one thread.

Things that apply to the 1.9 AAZ like on the 1.6TD

Pump governor mod:

http://vwdiesel.net/phpBB/viewtopic.php?t=1758

Larger downpipe and freeflow exhaust:

70mm dp:

http://www.morninglight.nl/a3/dp1.jpg

60mm exhaust:

http://www.morninglight.nl/a3/exhaust2.jpg

I've used one cherrybomb muffler because the sound was a bit over the top with the K24 and the larger exhaust.

And last but certainly not least an intercooler with large plumbing, I've used a Renault Master (2.8TD) intercooler (30"x12"x3") with 2.25" plumbing.

Turbo:

A 1.6TD's KKK K24 turbo fits when you saw a piece off intakemanifold (useless piece of support for something) and turn the compressorhousing a bit so the bumps are like this:

http://www.morninglight.nl/a3/k24t1.jpg

(the part that has to be removed from the manifold is just left of the compressor housing)

The last problem is the oilreturn, I used a piece of the 1.6TD oilreturn (first bend towards the back and then down) and connected that to the part already on the engine with a piece of 12mm (internal size) hydraulicshose and 2 clamps.

When your done with this you'll need a stronger clutch  


I'm open for comments and ofcourse, your mods..  

[TD_vento]

Ok I have a question about tunning the fuel pump.  I read the one in FAQ (for 1.6td) and printed a copy, when im in front of my 1.9td pump some of the screws are different.  Can somebody number the screws like in the Faq thread so people like me odnt get confused     I have connected number 4 to 3 but unsure of the 1-2 and the rest of the screws.  If anyone has a better picture put it in.

thanks

[Maarten]

My pump looks the same as yours so don't worry about 1 and 2.

6 is for tuning down your idle when you have screwed in 5 for more fuel (idle get higher by doing that) Screw 5 is located in your picture below the banjo on the LDA lid that connects the line from the intakemanifold, you see the flattipped screw pointing to the right?

[TD_vento]

Ok i edited my pic, screw 7 i think it on the back of the pump next to the block, or is that the screw for adjusting the start riching lever?  And i dont know about 8.

Ps i added a air filter( the mesh type) and the sound of the turbo wizzing it feels nice, also response feels better.

[Maarten]

5 is correct on your pic... when you look over 5 from the side you'll see 6. t is located behind the LDA if your standing in front of the car.

6 in your pic is for adjusting max throttle travel, play with it and see whats the difference.. I removed it

[TD_vento]

what about 7 and 8 do we have them on our engines??

[Maarten]

Screw 7 is for the coldstart advancer.. 8 is for adjusting the idle, it hold a lever that is just behind the returnline on the picture, another screw is about 3 cm to the right that needs to be screwed in to keep the lever in place when you screw out 8.

[TD_vento]

ok got a pic of the back of the pump,  which is screw 7 and 8?

[TD_vento]

bump anyone

[Maarten]

7 is the one with the spring, 8 the one next to it

[TD_vento]

you the man, thanks