1.9aaz swap motor on the way. need help

[Smithlawncare677]

my search isnt working at the moment soo
few questions
1 were can i buy a book on the Canada aaz 1.9
2 do i send a positive wire to trigger the fuel solenoid
3 what size lift pump do i need to supply this engine (what psi and gph)
4 what size intercooler
 5 is this kit worth buying

[Smithlawncare677]

and will a v6 toyota rad cool the 1.9?

[RunninWild]

A 24" or larger cross section rad is suggested. That being said you want quality fans. I have a 26" rad with dual 12" ebay slim fans and my engine was overheating when ripping up hills.

You don't need a lift pump. I bought a cheap one from eBay for like $12 that I only power when bleeding the system. Makes it much easier and can remain inline without obstructing fuel flow when it's not on.

From what I've heard you don't need a huge intercooler.

Yes 12v to fuel/timing solenoid on the pump.

The 1.6td and 1.9td are almost identical you would be fine with a book for either although most of the information youd need can be found online for free.

What kit are you talking about?

[Smithlawncare677]

as far as a lift pump,,  on my 5.9 vp truck i have to run a lift pump to keep the injector pump supplied.? so thats not needed on these motors.

i tried to post a link from ebay that was in a blue box that had a bunch of timing tools in it. the kit cost around $76

[RunninWild]

You don't need timing tools with the aaz. You can set the pump timing by pinning the pump while you set the mechanical timing. Advancing the timing by trial and error can be done fairly quickly and easily.

As long as your fuel system doesn't have any leaks it shouldn't loose prime when sitting.

[Smithlawncare677]

maybe its just the bigger pumps.  all the trucks i have built have had lift pumps to keep the injector pumps supplied. can anyone else chime in to give me a answer as to the difference in applications

[RunninWild]

I dont know about the differences but the 1.6td/1.9td idi vws didn't come with any electronic fuel pumps. Maybe it has something to do with the direct injection system? At any rate you won't need one. Most people done run any kind of a primer pump and bleed the system with a vacuum on the return line from the injection pump.
http://m.ebay.ca/itm/12V-Electric-Fuel-Pump-Low-Pressure-Bolt-Fixing-Wire-Diesel-Petrol-HEP-02A-NEW-/321596330401?nav=SEARCH is the one I used.

[Smithlawncare677]

what do you think about this   http://www.dakotadigital.com/index.cfm/page/ptype=product/product_id=129/category_id=287/mode=prod/prd129.htm

[RunninWild]

There is no sensor on the flywheel. You want the one that will convert the signal from the w terminal on the alternator.

[vanbcguy]

maybe its just the bigger pumps.  all the trucks i have built have had lift pumps to keep the injector pumps supplied. can anyone else chime in to give me a answer as to the difference in applications

It has a lot to do with the size difference between cars and trucks and the location of the fuel tank versus the pump.  In your average VW the tank is up under the back seat, ie above the floorpan.  That means it is about the same height as the engine.  Most trucks have the tank under the bed meaning it's typically below the height of the frame rails while the engine is mounted on top of the frame.  The result is fuel barely needs to be lifted at all in a VW while it often has to be pulled up a couple feet vertically in a truck.  Then add the relative length of the pickup versus a VW and you can see why a lift pump is necessary.

It's not a bad idea to add a lift pump on a VW but it's hard to find anything small enough that will work.  The VE injection pumps have pretty substantial flow requirements since they use fuel for cooling purposes.  Flow wise you need the same size feed pump as you would for a Cummins with a VE pump.  I've had good luck with a Facet Posiflow pump, my specific model is rated at about 40 GPH. That's about the minimum you can get away with.  Anything smaller will be restricting the fuel flow.

[RabbitJockey]

You don't need timing tools with the aaz. You can set the pump timing by pinning the pump while you set the mechanical timing. Advancing the timing by trial and error can be done fairly quickly and easily.

As long as your fuel system doesn't have any leaks it shouldn't loose prime when sitting.

this isn't true, aaz came with a few different style injection pumps depending on the year, only one of them doesn't "need" the timing tools.  but really you should have them for any style you have.

aaz doesn't need a lift pump either.  and the bentley for a mk3 car usually covers the aaz engine.

[Smithlawncare677]

search is busted and google isnt helping much. what the turbo options for an aaz. or just un cap the wast gate and crank the fuel? i have a set of head studs aready!!.

[RunninWild]

Aaz usually came with smaller turbo's like a t1 t2 or k04 or k14 I think. Blocking the Wastegate wouldn't be the best idea as they arnt very efficient at high boost. Manual boost controllers are cheap and can let you get a safe amount of boost. You can swap a t3 or k24 from an 1.6td but they are quite laggy. Newer turbo's like the vane controlled ones from tdis are great but require a bit of work to make the vanes function properly. The holset he200wg seems to be the turbo of choice at the moment.

[Smithlawncare677]

Where should I search for buying one?