!.6TD JX pump on AAZ

[Gizmoman]

Nothing wrong with asking questions.
Not sure about it but My AAZ with the 1.6 pump (like that when I bought the van) had a sheet metal mount. I bought a used block and it came with a cast mount which I believe was for the 1.9 pump but mine fit perfectly. With the cast bracket, I was also able to use the stock AAZ timing belt covers as well.

[AAZTristar]

So I checked, and mine has the stamped steel mount. You're saying that the AAZ pump should fit?

[Gizmoman]

So I checked, and mine has the stamped steel mount. You're saying that the AAZ pump should fit?

I can say my 1.6 IP fit the cast AAZ bracket. This is my first VW diesel so I can't say 100%
Here is a shot of my 1.6 IP on an AAZ (and I assume a 1.9 IP) mount.

[Yukon Syncro]

My JX engine reached the end of it's life so putting a AAZ into my Vanagon. It is a bit of a mixture of parts, many of the bits off the JX are being reused, the injection pump (was rebuilt by Giles, and the AAZ injection pump was missing on the engine I got), the JX exhaust manifold and exhaust, and airbox. Going to use the AAZ turbo since the JX one is done. Also going to have turbo adapter plates made up for using the AAZ turbo to match up to the JX exhaust manifold.

My question is regarding using the JX injection pump, and injectors and lines. Are there any issues with fitting the injection pump, injectors and lines? It seems that people who do this make it work by re-bending the JX lines, is this all I need to do, or am I missing something? Sorry if this is an obvious question but this is my first diesel too.  Thanks so much, been lurking long time and learning so much from the forum and figured I would add to this thread versus starting a new one.

[Yukon Syncro]

Another question, with a Syncro does the deck lid hit the JX injection pump when it is on the AAZ or does it clear lid?

[libbydiesel]

The JX pump (or AAZ pump) will fit in either the AAZ bracket or the JX pump bracket provided the sprocket that matches the pump is used.  You will need to bend the JX injection lines to fit the taller AAZ block and you will need to bend them more if the AAZ injectors are used as they are taller.

The injection pump mounts in the same location relative the chassis regardless of whether it is bolted to a 1.6 or 1.9.  The difference in the 1.9 block height is at the head gasket surface which is above the injection pump mounting location.  Regardless, there is not any issue with any injection pump hitting the doka engine lid.  There's plenty of clearance in a doka for even the normal LDA pump. 

[Yukon Syncro]

Thanks so much, for a regular vanagon, and not a doka,  is there an issue with hitting the engine lid with the JX injection pump on the AAZ engine block?

[libbydiesel]

Sorry, I must have been tired.  For some reason I translated Syncro as Doka, weird.  Anyway, to answer your actual question...  No, the JX pump will not hit the lid on an AAZ in a syncro.  Again, the pump is mounted in the same place relative the chassis on both the AAZ and the JX.  The JX pump does not hit the lid on a 2wd vanagon which has the engine mounted 1.5 inches closer to the lid.  Mounted on an AAZ in a Syncro, the JX pump would have another extra 1.5 inches of space above and beyond the clearance in a 2WD vanagon.  I don't even think the 'normal' LDA pumps will hit the engine lid on a Syncro.  Only the normal LDA pumps interfere with the lid when installed on a 2WD vanagon.  Even then, it's a small issue that is solved very easily.  The top of the pump does not even protrude above the top of the ribs of the lid so a little cut and a piece of sheet metal later makes it a non-issue. 

[burn_your_money]

The JX pump (or AAZ pump) will fit in either the AAZ bracket or the JX pump bracket provided the sprocket that matches the pump is used. 

All 1.6 brackets have a 50mm mounting diameter. AAZ has either 50mm or 68mm. The 68mm ones have a 2 piece timing belt pulley like the ALH engine.

[libbydiesel]

Good catch.  I tend to forget about the larger snout AAZs.

[Yukon Syncro]

Thanks so much for the help you lot rock!

[AAZTristar]

To answer my own question, I was able to mount the Giles rebuilt AAZ pump onto my 1.6TD/AAZ mongrel with no problems. Everything matched up perfectly. Feel much better about the pipe setup, just need a little tuning to get the smoke right. (too much black on acceleration)

http://images.thesamba.com/vw/gallery/pix/1229339.jpg

Now I just need to fix the hot engine problems I'm having , I've got a oil cooler setup on order. Hope that will fix it. Then it's on to boost controller, gauge, intercooler, EGT gauge, tach gauge, etc.