Advice sought

[CdnVWJunkie]

Hi-

  I'm new to this forum.  My ride is a '95 Passat Variant 1.9L TD aaz engine.   Over the next few months, I'm going to be upgrading the cars performance and would like some advice.  I've read Smogs suggestions, as welll as Dv8ster (sp?) which were both very informative and well written.

 Question 1.  I have a number of used injection pumps in my garage, is there any easy way to identify which models they came from?  

Q-2.  My car has a KKK turbo on it, less than 5 tkm on it.  It seems to spool nicely after 2500-3000 rpms but being a smallish diameter turbo should it not be spooling much sooner?

Q-3.  At some point I may install larger injectors or plunger in the pump.  What specs would my engine have and what can be retrofitted with parts that are availablesemi-regularily (read: not hens teeth scarse)

Q-4 - Last question... for now     What sort of performance figures have people achieved with the 1.9 aaz engine without sacificing drivabiliy/reliability?

 Cheers.

Rob

[QuickTD]

 Question 1.  I have a number of used injection pumps in my garage, is there any easy way to identify which models they came from?

You can ask Marc (redrotors) on this forum, he's in the know. If you just want to know the plunger size I believe 4th character in the part number indicates this, for example a part number starting with VE4/9 would be a 4 cylinder, 9mm plunger pump.  

Q-2.  My car has a KKK turbo on it, less than 5 tkm on it.  It seems to spool nicely after 2500-3000 rpms but being a smallish diameter turbo should it not be spooling much sooner?

If it is a KKK-K03, I would expect it to spool much sooner. Mine begins to make boost just off idle and hits 15psi by 1500-1800rpm. The fueling level plays a part in how soon the boost comes on but I would expect a stocker to produce full boost by 2200rpm. You could have issues with the wastegate hanging up, improper adjustment of the EGR switch, or possibly a stuck EGR valve. Worth looking into. Do you have a boost guage or are you going by "seat of the pants".

Q-3.  At some point I may install larger injectors or plunger in the pump.  What specs would my engine have and what can be retrofitted with parts that are availablesemi-regularily (read: not hens teeth scarse)

Your engine has a 9mm plunger. Depending on your pump model, a TDI plunger and head may fit. The jury is still out on injectors. Smog has GTD nozzles available in the classified section. I am going to get a set and experiment. I'll let everyone know how it works out. You may not need injectors or a larger plunger, depends on your HP goals.  

Q-4 - Last question... for now     What sort of performance figures have people achieved with the 1.9 aaz engine without sacificing drivabiliy/reliability?

My car is intercooled, running 15psi boost on the stock K03, BMW524TD aneroid pin and some pump adjustments. It produces little smoke and G-techs consistantly @88whp using a guesstimated 3000lbs as the weight. It has been making that power for over 150000km without major issues. My guess is it could stand over 100whp reliably.

[CdnVWJunkie]

Thanks for your response QuickTD.  

 I'll check into the numbers to see what sizes these pumps I have are.  

 I currently don't have either a boost guage or a pyrometer, both of which I'll be purchasing shortly.  I've had it recommended to me that neon pillar mount guage pods work, guess I'll try that out and see.  I don't really want to give my change holder/ash tray.

 Is your engine a 1.6 or 1.9?  What is it in?  My passat is a little on the heavy side but has a lot of nice amenities that my old golf didn't.  As for power, due to the weight I'd like to get a much as I can get without sacrificing reliability.

Rob

[QuickTD]

Is your engine a 1.6 or 1.9? What is it in?

Sorry, it's a 1.9TD in a '97 jetta.