Ive been a member of the forum for a while now and although ive posted a few of my mods on another thread i thought I start a progress thread to show my mods and to gather everybody's opinions and advice.
My car is a '96 Passat estate with a 1.9TD AAZ, 165000 miles and in pretty good health. After reading the "how to tune the 1.9td" post I decided to have a go at making some mods.
First off I decided not to touch the solenoids on the pump, mainly because of the fact that it is fitted with an immobiliser and ecu which i didint want to screw up or flag up the EML on the dash!
I borrowed a very accurate digital boost pressure gauge from work (the proper VAG tool!) so take some readings
Started by taking a max boost reading before touching the pump =0.89 bar (12.9 psi)
Then turned the fuel screw by 1/2 a turn after breaking off the anti tamper tabs, and adjusted the idle back.
=0.94 bar (13.6 psi)
Finally I adjusted the wastegate and gave the fuel screw a further 1/4 turn Ive ended up with 1.09 bar (15.8 psi)
The result was a definite improvement, although the car still isn't going to break speed records, it certainly feels more torquey and drivable!
I then disconnected the EGR valve and blanked it off, making a quite considerable difference to the drivability of the car for such a simple mod.
The only problem I have had after running the car for a couple of months is a slightly high idle from time to time, which Ive solved by turning the fuel screw back by a 1/4 turn.
Anyway this weekend I had a really good find at the local scrap yard. A '91 passat with a 1.6 TD intercooled engine (the engine itself was dead after a snapped cambelt)
Got the intercooler hoses off the passat and a large intercooler off a Volvo 7series TD which I hope to fit infront of the radiator(the passat intercooler was damaged)
Only £15!! Bargain!!
Also somehow the boost pins out of both cars ended up in my tool box :roll:
AAZ to left, 1.6TD middle, Volvo right
The 1.6td pin and volvo item are actually the same but seem to have different spring rates. Look care fully and you can see the marks on the pins at different levels.
The 1.6td spring seems to allow some more movement. The marking on the AAZ pin compared to the 1.6td is virtually the same, so despite the AAZ spring looking totally different its probably around about the same rate.
Anyway I fitted the new boost pin using the AAZ spring at the least aggresive setting first (couldnt tell any diffrence), and have now turned it about a 1/4 turn which gives just a puff of smoke on boost, which has made a definate performance advantage, without the engine producing too much smoke.
Next job is to get the intercooler fitted, before any further adjustments. Watch this space!!
Topic: My AAZ Passat (Read 4791 times)
