AAZ Conversion

[stefduff]

I have a 1.6GTD Mk2. The head has gone on it this weekend, think its a cracked head.

So contemplating putting the AAZ in, is there any conversion guides about anywhere? I've looked in the usual places but can't seem to find one.

Any help appreciated, Stef.

[R.O.R-2.0]

un bolt the 1.6, bolt in the 1.9..

[Thezorn]

There is a bit more then zero difference in swaping them, Only thing might be the right motor mount with are different from the 1.6 to the 1.9s, but then that it would be super easy.

[R.O.R-2.0]

well, it bolts it in with the right stuff on it. its all bolt on stuff.

take the important accessories off the 1.6, and fit them to the 1.9, then drop it in.

dont forget about the exhaust. the 1.9 is a taller engine, and needs a longer down pipe.

[stefduff]

What do you suggest i take from the GTD engine?

I've read so so many contradicting things about what to swap, some clarification would be great!

You say one engine mount is out, is it swappable with the GTD engine to bolt in?

Stef.

[R.O.R-2.0]

basically, the only difference in the actual engine block and head, are the block height, intake port shape, center bolt valve cover, and of course displacement.

how complete is the AAZ?

some people like running the GTD pump & injectors on the AAZ.

i would prolly use the GTD turbo also..

[Quantum TD]

Dear God! Is that the car in question? I thought my 1982 Quantum/Passat/Santa was hideous. Yeetch.

[stefduff]

Dear God! Is that the car in question? I thought my 1982 Quantum/Passat/Santa was hideous. Yeetch.

Thanks for the help....haha.

Its going in this,

basically, the only difference in the actual engine block and head, are the block height, intake port shape, center bolt valve cover, and of course displacement.

how complete is the AAZ?

some people like running the GTD pump & injectors on the AAZ.

i would prolly use the GTD turbo also..

Its got everything as far as i'm aware, downpipe too, gearbox, but been told the gearbox is rubbish.

I'll be getting a few pics before i buy it to see what condition its in.

[Laurentian]

Should drop right in.
Ditto on exhaust.
I have a'91 jetta with AAZ in it.
Running the older MKII alt / pully set-up. If you want to run the serp.
set-up you will have to clearance the stamped sheet metal frame tube
by either cutting and welding a new patch or pounding a gap with a
large hammer trick. Some say you cabn use spacers on the subframe
somewhere but am skeptical. I ran the MKII set-up to keep my frames
strong and straight.

[stefduff]

Hello, i have changed the engine this weekend from GTD to AAZ.

Everythings bolted in fine, gearbox had different driveshaft spacings in so i've had to change those.


It don't run at the moment though, main problem, i think, being the wiring is completely different.
I've managed to find places for 90% of things but theres still a few wires on the aaz that have nowhere to go. Mainly on the fuel pump there are 3 different cables going into the AAZ fuel pump and i have one cable spare! The wire i have spare is the one that went to the GTD Pump, its black and was the only cable going onto the GTD pump.

I think that this wire is whats holding it off running. Anyway, i have a pic of the AAZ fuel pump wiring connections and any help fathoming them out woiuld be great.


Thanks, Stefan.

[Vincent Waldon]

Kinda hard to tell from the picture, but it looks like you've got the late model AAZ with the "start of injection" sensor where the timing gauge would normally go.

If so, this engine needs the original electronics to run... particularly the control module that runs the pump, dials in advance (which is likely another one of the wire connections to the pump you are trying to sort out.. sensor-looking thing on the backside of the pump), etc.  This was VWs last pump before full electronic contol ie TDI, and it's not a 1-wire-to-run system anymore at this point.

Might be worth PMing user "Baxter"... those particular pumps/engines are a European thing and he's weighted in on them in previous threads.

[stefduff]

Guess thats not really what i wanted to hear!

Is it possible for me to swap the fuel pump from the GTD engine to use on the AAZ engine? Hence, hopefully solving my problem?


From the sticker on the timing belt cover the engine looks like it was made mid 1996. So i guess quite a late engine.

I'll pm baxter now.

Thanks, stefan.

[arb]

Yep, a simple single wire (or no wire if you want to replace the fuel cut-off solenoid with a mechanical fuel shut-off valve to have a pure mechanical fuel system (other than GP)

By the way, what that apparent forum www.cumbriavag.co.uk for ? Air cooled VW's ?

[Vincent Waldon]

Is it possible for me to swap the fuel pump from the GTD engine to use on the AAZ engine? Hence, hopefully solving my problem?

It's possible... a couple of small wrinkles include:

- the GTD delivery valves are likely shorter than the AAZ ones so your hi-pressure lines may need a bit of rework
- the pump mount itself may need to swap over, since the GTD snout size is different.  You may be fine... I can't remember off-hand which snout is bigger.
- the mounting hardware will need to swap over, since the GTD pump needs to rotate to set the timing (whereas the AAZ pump probably had an adjustable sprocket)
- AAZ injectors pop at 15O bar rather than 155 like the GTD, so you many need to retard your timing a little bit for best running