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General Information => Troubleshooting => Topic started by: jtanguay on November 27, 2006, 06:08:26 pm
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fitting a 1.9TD AAZ injection pump on 1.6TD. just bought it today!
I am wondering if someone has ever done this swap? looks like there are a few extra's (apply 12v to the altitude compensator thing, etc)
I have 2 extra 1.6TD ip's (one needs rebuild for sure, other one... probably too!)
anything other than the boost pin that I should swap over? has anyone ran into difficulties with a 1.9 pump on a 1.6?
i'm hoping to just tear my pump out, plug this new pump in (primed of course) and fire her up after timing it.
oh yea it has a plastic collar piece on the fuel screw... hmmm i might just melt it off for fun! :twisted:
hopefully that diesel leaking on my coolant hose hasn't softened it up too badly... haven't been driving the car for quite some time now, and I just miss the diesel!!! i neeeeeeed dieeeselll
thanks for the help guys!
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well now that I'm thinking about it... isn't the camplate different in the 1.9 IP's??? but is that all I need to swap from the 1.6 IP ???
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my buddy made it work, before the turbo on the 1.6TD went south.
Modified the 1.9 IP bracket to fit the 1.6TD bloc at his job (diesel truck shop :lol: )
Worked #1
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makes sense that the bracket is different... thanks for the info! i have a parts car and have lots of pieces to play with :)
its really nice to be able to play around on a non rusty pump... i hate looking at rusty pieces with serial/part numbers all rusted out. plus they are just a huge mess!
now i have to allot more than a days work to install this pump (unless i get lucky) to get the bracket bit sorted out.
thanks again!
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okay well informations i have learned.
- 1.9 ip will fit the 1.6 block
- 1.9 ip and sprocket must be used. 1.6 sprocket will not work.
yay me! lol
cant wait to get this thing installed and timed... i'm going to have a breakdown if i dont get this working soon...
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should run real nice like
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cant wait to get this thing installed and timed... i'm going to have a breakdown if i dont get this working soon...
May as well make a DIY while you're at it, and make sure to let us know if it was worth it
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my thoughts exactly burn... i got a real nice deal on the pump... and i wanna make use of it :).
if its just the 1.9 sprocket, then that is nothing... i was scare of brackets etc... who knows if a bracket i made would hold up? lol probably slide or something and mess my timing right up hehe... i have a lot to learn still.. :lol:
one thing i have just thought of... is the rev limiter/governor... i'm going to see a 4500 rpm power loss right? i dont even think i've taken my car that high except a few times to break the rings in... i kinda baby my car..
once i get the sweet tranny installed too, it will help immensely. i find that 1st gear in my car is useless... the motor winds up too fast and i'm not going that fast by the time 4k rpm hits. my last jetta was real nice... no tach but my trained ear had a pretty good idea of where the engine was at. the gears were much taller, but the boost didn't come on till 3k rpm.
if the governor will limit my rpm to 4300-4500 rpm, i will just live with it... i'm not even going to try and mess with that for the time being. need to understand how it really works first. maybe i will tear down my spare and run it off a drill just to see how the springs affect governor movement.. :)
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well reading the diy guide for 'tweaking' the governor, it looks a lot simpler than i had imagined. but if i get the wrong length for the intermediate spring, my idle will be all screwed... right? maybe i'll look into it while my sprocket is being ordered :)
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you could always put the 1.6 governor on
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hmmm about the 1.6 governor... i guess that could work :) i'll see just how big my balls are if/when i decide to take a crack at it though... :lol:
i just went and ordered the parts i needed. got a spring washer, the retaining bolt, etc... pretty much everything on etka to hold the sprocket on, and the sprocket itself. even the little woodruff key :)
there wasn't a special one i was supposed to buy right? such as a 1.9 from 93 rather than 97?
oh and i checked the retail price on a pump... $3300... damn i got a good deal! 8)
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Does the inj pump housing have threads or slots for the 3 mounting flange bolts?
I have a spare 93-95 pump mounting bracket and probably sproket too.For ordering the parts you would have needed to know which style pump you had 93-95 or 96-97?
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i told the guy it was out of a 97 jetta... hopefully my pump is from 97 and up, and hopefully the parts i am ordering will work!
hmmm maybe i will have to go see you andy, and check out my parts.
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well met up with andy2 tonight... the pump will not work :(
its the 93-95 1.9TD pump. probably would have started leaking anyways... oh well...
the bracket won't even line up properly with the pump because of the timing advance cover in front. :(
the actual pump shaft sticks out considerably as well, and the 1.9 sprocket will not recess enough to compensate for it. modifying the pump sprocket and the bracket would work... but not if the pump is just going to leak down the road anyways...
well i was the test guinea pig... but at least we know now! should probably get some pics to better explain the issues... but i must retire!
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You didn't tell them the good part?? Modded pump and good turbo :wink:
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You didn't tell them the good part?? Modded pump and good turbo :wink:
hehe you're right! i'm sure happy to finally meet you, and check our your monster 1.9 :)
hehe i'll be sure glad once this leaking injection pump nightmare is over with... just my luck the hose that got diesel dripped on for the weeks it went unnoticed will burst... and i will need to re-fill my system :(. hopefully the 1.9 pump will do you more good than it has for me! :)
and yes the turbo! lol now you know what i meant by the fins being mangled... the turbo probably would have worked... lol probably being key word here... hehe! I cant wait to get that thing on. :D
many thanks to andy for all his help!
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Where is your pump leaking?
Andrew
right at the head... pretty soon the whole pump is going to die i think... it still runs pretty strong though.. i had to put a plastic bag over my coolant hose to catch the dripping diesel... damage is probably already done though... but that probably won't break until summer, when its much more fun to change :roll: :lol: .
the car is starting to give a really rough idle when hot. almost like a miss... when its cold it idles really good and feels like it has lots of power!
we'll see how my car runs with andy's super pump... full fueling until 4500 rpm!!!!!! i'm definitely going to need my pyrometer installed... thats nuts!
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thanks for the tip :)
i was really considering just fixing where its leaking from, but with what everyone is saying (that other parts on the pump will eventually leak) i might as well swap my pump for something that will not leak... ever :)
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Change your hozes when you have the pump off. It makes it a whole bunch easier. Especially if you have the spring clamps. That short one down on the pump is the funnest one.