AAZ Injector Lines - let em relax! - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• AAZ Injector Lines - let em relax! by Gizmoman on 15 Jan, 2014 18:25
• I've been taking my van to work every morning to get the "bugs" worked out after the refurbish.
  It's a 40+ mile round trip with some good freeway grades, and high speed traffic so it's a good test.
  
  I adjusted the IP timing last weekend and forgot to loosen up each nut and let the lines "relax" to their new position.
  
  Well, #2 line cracked this morning just before I arrived so I need a new line. I think I'd like to replace the entire set as they have all been stressed and I don't want to worry about them in the future.
  
  I found a set on e-bay http://www.ebay.com/itm/VW-Volkswagen-1-9D-1-9TD-Diesel-1Y-AAZ-Fuel-Injector-Pressure-line-kit-/171098306000
  
  $170 + but would like opinions from other or possibly more reliable sources.
  
  Till I get them, the van is parked at work locked up tight. Prompt responses appreciated!
  
  Engine is a 1.9 AAZ
  *EDIT* Will AHU (or other styles) work? I found some for 70 bucks on ebay as well (I already know TDI won't fit).
• #1 by 410 on 15 Jan, 2014 19:15
• Only the AAZ lines will fit.  AHU lines are very different.  I would look for a set of used ones.  Shouldn't be a problem to get a good set for $50 shipped.
• #2 by Gizmoman on 15 Jan, 2014 21:13
• Thanks, that narrows it down. As far as getting used, I'd rather have new when it comes to parts that can leave you stranded. The e-bay set I linked to says they are new (and for as AAZ) but I have no idea what the quality is.
• #3 by wolf_walker on 15 Jan, 2014 21:17
• I've seen a bunch of aftermarket ones, presumably asian, for IDI's, no idea on quality.
  Unless you stress one or do something unkind to it they don't wear out.  I'd buy
  OE used too, there's a place in Cali that imports a bunch of 1.9's, I forget the name. 
  Mine are re-bent off a TD, single stage injectors though, think they are shorter.
  Been on there for years, and were on the TD since 85.
• #4 by Gizmoman on 16 Jan, 2014 06:05
• Quote from: wolf_walker on 15 Jan, 2014 21:17

  I've seen a bunch of aftermarket ones, presumably asian, for IDI's, no idea on quality.
  Unless you stress one or do something unkind to it they don't wear out.  I'd buy
  OE used too, there's a place in Cali that imports a bunch of 1.9's, I forget the name.  
  Mine are re-bent off a TD, single stage injectors though, think they are shorter.
  Been on there for years, and were on the TD since 85.
  

  I emailed the outfit you mentioned - no response yet.
  
  Too bad I have to learn everything the hard way. Used is OK I guess but there's no telling if they have been stressed as well. Doing a bunch of different searches yields lots of guys wanting them but none selling them.
  I was going to move on the ebay set and the listing says he has 9 in stock but he's not selling them right now. . .?
  
  I might remove mine and tig-weld the crack. Sounds silly but I don't know what else to do. I have no doubts I could tig it - just worried about the heat/scale on the ID messing up the flow or plugging the injector.
• #5 by theman53 on 16 Jan, 2014 06:17
• CRSMP5 tig welded his AHU #3 and it has worked fine. I know your reservations though and understand. Might be good to have them as a spare.
• #6 by 745 turbogreasel on 16 Jan, 2014 14:18
• Maybe anneal them?
• #7 by vanbcguy on 16 Jan, 2014 16:41
• I bought a set for my 1.6 made by Cohline. They're a German company. Might try seeing if they make a set for the AAZ, things are much easier with a part number.
• #8 by Gizmoman on 16 Jan, 2014 16:59
• Tig welding is off the list. . .
  
  
  I guess there's no harm in trying though - can't hurt it at this point
  
  Anyone have a part number? This is line #2
• #9 by Gizmoman on 16 Jan, 2014 19:16
• I just bought the set I first listed from the e-bay seller - the guy replied to my inquiry and discounted them a bit as well. Hopefully I'll have them by mid next week.
  
  Learned a hard lesson about loosening them up after moving the IP. After hunting for a set (new or used) for many hours and handing over a good chunk of earnings, these bits will be handled with serious respect in the future.
• #10 by Spokerider on 16 Jan, 2014 19:24
• Good grief those are pricey pieces of metal........
  
  So the idea is to loose off all 8 nuts before adjusting [ rotating ] the inj pump timing?
  Trying not to spend any more $$ than required at this point of my aaz assembly.
  
  
• #11 by Gizmoman on 16 Jan, 2014 21:14
• Quote from: Spokerider on 16 Jan, 2014 19:24

  Good grief those are pricey pieces of metal........
  
  So the idea is to loose off all 8 nuts before adjusting [ rotating ] the inj pump timing?
  Trying not to spend any more $$ than required at this point of my aaz assembly.
  

  
  Yup, that's what smart people do.
  If your patient, you might find them used somewhere for a lot less. Best thing to do is treat the ones you have with a lot of respect.
  They don't care to be twisted, then vibrated while under extreme pressure much.
• #12 by Blue Haze on 17 Jan, 2014 08:14
• You might try Quality German Auto Parts in Ontario, Ca  phone 909-391-6979.  He imports motors from Germany I think this is the person that Wolf Walker is referring to.  I bought my AAZ from him.
• #13 by Mark(The Miser)UK on 17 Jan, 2014 09:17
• Quote from: Gizmoman on 16 Jan, 2014 16:59

  
  Anyone have a part number? This is line #2
  

  Line #2 for AAZ is 028 130 302 C. Not sure if 1.9D/Eco fits which is 028 130 302B
  
  I could be wrong , but that break being up at the #2 injector is a result of multiple tightening/undoing with the spanner and twisting the line. Best to tighten with the clamps off, if you are having slight fuel leak issues so that you can see if you are adding twist to the pipes with the final tightening...
  
   I don't think that moving pump from 1.05 to 0.95, without slackening of lines would do this, unless they were initially clamped somewhere in the 2.0 direction. Not really likely though...
  When experimenting, dynamically, I always slacken all 8 nuts after each move. 0.1mm or 5 thou is well within limits.  
  Here is a great idea of mine given to you, and others freely...
  
   On your new set of lines, or even a known good old set:-
  
  Take a permanent marker pen, and mark a line longitudinally from the nut of each fuel line back about 2" or so.
  Do it at some convenient and referenceable position, for example on injector ends  facing the timing belt, and continue around the bend to the topmost part of each line. Do the same thing down at the pump end. you will now be able to see what is twisting, and why.
• #14 by wolf_walker on 17 Jan, 2014 09:38
• I would admit to polishing both sides of the flare on each end and lubing them to encourage the nut turning and not twisting the pipe with it.
  
  I've been accused of being fussy about some thing.