help with throttle linkage for a vanagon aaz swap

[paolomarks]

 Hello all,
I'm putting an AAZ (1996)in my diesel vanagon(1981).  If I use the stock diesel Vanagon throttle arm  it sits higher up due to the longer throttle shaft on the AAZ. I thought initially that I could switch shafts, but the "arm" on the end of the shaft is longer on the AAZ and connects to the linkage in a slightly different place, don't think I should mess with that.   What should I do?   On a related note, will the LDA clear the deck lid?, if not can I lower the engine mounts slightly?  Thanks, Paolo.

[GEE-BEE]

Ask Justin

greaseworks.com

[R.O.R-2.0]

Hello all,
I'm putting an AAZ (1996)in my diesel vanagon(1981).  If I use the stock diesel Vanagon throttle arm  it sits higher up due to the longer throttle shaft on the AAZ. I thought initially that I could switch shafts, but the "arm" on the end of the shaft is longer on the AAZ and connects to the linkage in a slightly different place, don't think I should mess with that.   What should I do?   On a related note, will the LDA clear the deck lid?, if not can I lower the engine mounts slightly?  Thanks, Paolo.

the Vans got a fuel pump with a different style throttle arm, and a side mounted LDA..

im pretty sure your gonna have to bash a dent in your engine lid to clear the LDA, and the throttle arm is shaped way differently too.

the normal throttle levers are straight, the van unit is bent at a 45-50* angle and sits down beside the pump..

[R.O.R-2.0]

After '82 the engine lids are fiberglass and so attempting to "bash a dent" isn't very effective.  

There are quite a few variations to the AAZ accelerator lever/springs and so a picture will get you much more accurate info.

Brickworks sells a little AAZ lever extension, but unfortunately they do not ship to the US.  You might search their site for more ideas.

IMO, the best solution is to remove the arm, bend it, weld on an extension and drill/tap it to accept the accelerator ball.  That way the correct geometry is maintained to use the diesel vanagon accelerator cable (or gas van accelerator pedal assembly) and use the full swing of the pedal (ignore the upper shaft coming off the lever as that is for the VNT vane actuation).  



Another alternative is to just bend the AAZ arm down and flip the cable ball connector to under the lever.  The downside to that approach is that it gives less pedal articulation and the angle for the cable is less than ideal.

LMFAO.. good to know about the fiberglass engine lid.. yea, cant easily bash a dent in that one!

[Quantum TD]

I think the BrickYard sells a small box that you can buy to cutout for the AAZ pump. Check out their website. It will give you an idea.

Ideally, you could take the AAZ guts and a 1.6TD T3 LDA and throttle-lever housing and make one pump that clears it all.

[R.O.R-2.0]

LMFAO.. good to know about the fiberglass engine lid.. yea, cant easily bash a dent in that one!

He says in his initial post that he has an '81 so he likely has the metal lid (unless someone replaced it) and so BFH could be an option for aneroid clearance.  The accelerator arm is better altered tho, regardless.  

i believe ive read somewhere that the accelerator arm cracks if you bend it without heating it up?

maybe not? but still?

is it best to bend it, or modify it?

[R.O.R-2.0]

I've bent a couple without issue.

ok, sweet.. just wanted to touch on the issue of it cracking, or if it even did for that matter?

[blackdogvan]

I had a brickwerks arm sent to a buddy in the UK. Yes a bit spendy, yes it can be easily done but its a nice piece & ya... i like a nice piece.
I still had to carve out some foam though.

[R.O.R-2.0]

I had a brickwerks arm sent to a buddy in the UK. Yes a bit spendy, yes it can be easily done but its a nice piece & ya... i like a nice piece.
I still had to carve out some foam though.

is that a REAL PP intake manifold?! 

[paolomarks]

Thanks guys for the help especially the pics! Couple questions, first for Libbybappa, when you alter the arm as in your picture, do you have to alter the rear cable mount/bracket too.  Then for Blackdogvan,  My pump has 2 springs under the throttle arm. In your pics there's just 1.  Is your pump different or does the Brickwerks kit supply the parts to change this setup?  Finally, a question for anybody, instead of popping a hole in the engine lid what about lowering the engine mounts. I'm thinking leave the transmission mount as is but angle the engine/tranny down then relocate holes or add shims to the 4 other mounts.  The only issues I can think of are shifting linkage, ground clearance and axle location. How much do you have to lower in order to clear the LDA? 1inch? 2 inch?  Anybody done this or have an opinion?  Thanks, Paolo