question about aaz -> 1.6TD injectors

[gldgti]

My AAZ is coming up on 230,000 km and i've been wanting to get the injectors pop tested for a while now - just to check - even though everyhting is a-ok - good fuel economy, good starting, not too smokey. Nonetheless, its due by any means.

Trouble is, i reckon i'm going to be far from able to get hold of anyone in australia that knows about the 2 stage injector setup.

Now, I actually have access to a pop tester at home, and a lot of shims etc - but I've heard that the AAZ injectors are different to set up - anyone able to confirm this?

My other option is to go to 1.6TD injectors, which is a possibility, and a lot easier to set up (i guess). Any votes for this idea? If so, what pressure would i et them for an aaz with otherwise stock pump? Ideas?

Thanks,
Aydan

[vanbcguy]

If you end up changing to 1.6 injectors you also need the 1.6 injector lines and the 1.6 delivery valves for the pump.  The 1.9 injectors are taller than the 1.6 ones and the delivery valves on the pump are a different length.  I HAVE seen brutally bent 1.9 lines with 1.6 injectors underneath them but that sounds like a really good way to have a line crack on you somewhere down the road.

[commuter boy]

I've swapped between 1.6TD and 1.9TD injectors on an AAZ without changing the delivery valves, as long as you use the matching lines for the type of injector you'll be fine.

[Vincent Waldon]

Now, I actually have access to a pop tester at home, and a lot of shims etc - but I've heard that the AAZ injectors are different to set up - anyone able to confirm this?

Yup... very different... not really within the range of the dial-type pop tester and the shims are even harder to find:



AAZ dual-pressure on the top, old skool 1.6 on the bottom.  AAZ has two breaking pressures, so two different shims, neither of which is the same size as the 1.6 version.

[neimis]

My AAZ ('92 Passat) originally came with the one stage injectors. About a year or two ago I upgraded to the two stage injectors, with new "GTD" nozzles, but to tell you the truth, I haven't really noticed any big change, or maybe any change at all! Stands to reason it should run better/smoother/whatever, right? But, I dunno, I don't really notice much difference. For whatever it's worth...

P.S. the two stage injectors needed different lines, as Commuter Boy said (and a deep well socket!) but other than that, it's a straight swap