AAZ TD tuning advice for a newby!

[johnboy]

Hi guys, great forum!

Ive spent a couple of hours browsing the forum and I was wondering if someone could give me a basic outline of the mods I can make to the AAZ engine.

I have a 96 Passat Estate TD with a later AAZ engine (with EGR) which I want to increase the performance of, while keeping reliability.
Id like to boost the power to around the level of the 90BHP Tdi without changing too many parts. Is this possible?

Although Ive tuned a few petrol engines and despite working in a VW parts dept, Ive never really worked on diesels before so all info would be appreciated!

[jtanguay]

first off.. delete the EGR.

[johnboy]

OK, what benefit will I see from ditching the EGR? Is it as simple as blanking off the EGR connections to the manifolds and any vacumn pipes?

Also found this link while browsing...

http://vwdiesel.net/phpBB/viewtopic.php?t=579&start=0&postdays=0&postorder=asc&highlight=&sid=6aaee06478055559febc40fcf1a4d895

...which seems to be the kind of thing Im looking for, however the pump on mine looks a little different...






Are the principles the same?

[jtanguay]

the principles are pretty much the same.

as for EGR, it basically dumps soot and sludge into your oil, as well as gums up your intake.

if you remove the intake manifold, you will see a lot of sludge buildup in it... cleaning it out might actually give you a couple of hp from better airflow!!  :lol:

[nogama3]

johnboy, i too have a td aaz engine in my mk3 golf and i went to the derv doctor in derby who increased the boost from 0.8 bar to 1.2 bar and increased the fuelling whih made my motor bhp increase from 75bhp to 95 bhp. give gavin a cal mate.

http://www.thedervdoctor.co.uk/

[johnboy]

OK, guys, Ive had chance today to properly compare my pump to the pics in the make your 1.9td faster thread.

Can you take a look at my pics compared to the originals and make sure Im on the right track!




My pump doesnt have numbers 1 & 2, so i guess i can forget about them!

Number 3, the fuel cut off solenoid...


Number 4 solenoid...



Number 6 and 7 are clear on my pump but is this screw number 5?


and Im guessing mine pump doesnt have number 8, but maybe you can see something i cant!



Also Ive been looking at what might be involved in removing the EGR system. Im guessing I can dump the whole lot and simply run a vac pipe between A&B

 
Will I need to do something with the wiring to the change over valve (pos8 on the etka screen) or can I just leave it plugged in?

Again all advice will be appreciated!

thanks to nogama3 too for the info, although id like to have a go myself first!

[jimfoo]

Sorry to somewhat hijack the thread, but what is the purpose of the shock absorber looking thing that goes between the throttle and pump body? Mine had one, but I took it off as it had absolutely no resistance.

[johnboy]

Good question! Mine also has no resistance so Im guessing its knackered! Im guessing its some kind of vibration damper??!

Also just noticed taht Ive put the arrow for number 3, the fuel cut off solenoid, in the wrong place, its actually below the immobiliser block I think!

[jtanguay]

i thought that thing was to eliminate the sticky throttle...

[johnboy]

i thought that thing was to eliminate the sticky throttle...

...Could be!

[johnboy]

Thought Id let you know how Ive got on.
First off I decided not to touch the solenoids on the pump, mainly because of the fact that it is fitted with an immobiliser which i didint want to screw up!
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 ive after adjusting the wastegate and giving the fuel screw a further 1/4 turn ive ended up with 1.09 bar (15.8 psi)
The result is a definate improvement, although the car still isnt going to break speed records, it certainly feels more torquey and driveable!

[nkb]

i think that shock thing is to stop the lever from snapping back and causing the abrupt engine braking. mine still worked but i removed it because it also hangs the revs between shifts

[windsnob54]

I'd also love to know the answer to the question of what should be done with the valve number 8 (POS in the diagram. I have this thing still in place but no wires attached.  Am I sacrificing power?

thanks

[johnboy]

I'd also love to know the answer to the question of what should be done with the valve number 8 (POS in the diagram. I have this thing still in place but no wires attached.  Am I sacrificing power?

thanks

Cant seem to find a definative answer to this. Ive asked a couple of the mechanics at work (I work at a VW dealer) and they dont know! One guy who might know is back from holiday this week so Ill ask him!

[nogama3]

Johnboy, my car is set up at 1.2 bar with the fuelling adjusted to meet the demand!
i hope that helps. apparently, it is quite safe to take it upto this level as long as the fuelling is adjusted.