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Engine Specific Info and Questions => IDI Engine => Topic started by: wpinnix on April 05, 2010, 01:15:06 am

Title: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: wpinnix on April 05, 2010, 01:15:06 am

Hello, I recently acquired this AAZ motor out of a 1997 Jetta, I will be putting in an 81 caddy. You can see from this picture, the engine was manufactured in 1996. The injection pump pulley is the adjustable type.

What tool do I use to lock it in place to replace the timing belt? You can see in the picture a square notch in pulley lined up with a round hole in the rear....

I believe the alternator pulley is clutched???....will spin separate from the shaft if given a quick spin by hand and grab. Has the part numbers F225355.6  

Also has a K03 turbo.....has play in and out....I plan on rebuilding. Any good places to get rebuild kit and 360 degree bearing thing?

(http://sealrockorchids.com/images/vw/PICT0011.jpg)
(http://sealrockorchids.com/images/vw/PICT0014.jpg)
(http://sealrockorchids.com/images/vw/PICT0002.jpg)

I also am wondering about taking off the wires that run to the top of the injection pump....can I just remove them and have it work?
(http://sealrockorchids.com/images/vw/PICT0016.jpg)

Thanks for any help,
Bill

Title: Re: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: burn_your_money on April 05, 2010, 09:11:11 am

Use a drill bit or something to lock the pump and then use a dial indicator and rotate the pump by the 19mm nut to fine tune the timing. I find 1.9s like 0.88mm-0.95mm advance

Those wires on the top are useless. You can safely delete them.

Title: Re: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: xsp2467 on April 06, 2010, 12:07:29 am

let me know if you need any help with the swap, i can give you a few pointers. I recommend you do the timing belt while the motor is out of the car. Dont forget the tensioner and while the motor is out i would also do the intermediate shaft seal. Your gonna like the AAZ in the truck it hauls a$$. I get all my turbos rebuilt by G-Pop shop they are in Arkansas they do a full rebuild for about $395 and have the 360 degree thrust bearing

Title: Re: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: GEE-BEE on April 06, 2010, 06:16:08 am

Dont forget the tdi crank mod, new aaz hoses ( coolant) autohausaz.com
search 96 golf aaz
you will need the hardline coolant hose to recovery tank
I have some 7 mm hose for you fuel supply to filter and return if needed

Let me know
[email protected]

I also have new intake ducts ( turbo to intake )and the right K7N filter assy # for your install

Where all here to help

GB

Title: Re: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: wpinnix on April 06, 2010, 11:18:25 pm

Thanks everyone for the pointers.

I have my passenger side motor mount fabricated. I'm doing the timing belt, tensioner, water pump, clutch, seals I can get to.....new hoses for sure. Just waiting on turbo to fab up the downpipe.

A couple of questions:

--Will 1.6 NA injector lines fit the AAZ? I have a new set and would be fortuitous....
--Trying to decide on Turbo (the K03 on there now looks like a screw or nut or something went through the vanes).....I've done some research, but everyone has a different opinion. Don't need much more than stock power, just something that is easy to work with and maybe has adjustable waste gate


Thanks again,
Bill

Title: Re: 1997 AAZ Injection Pump Timing, Clutched alternator pulley?
Post by: vanbcguy on April 07, 2010, 09:32:23 am

The 1.6 lines will fit if you also use 1.6 injectors.  The 1.9 injectors are a bit taller, so they need the correct lines.

The "gotcha" however is the 1.9 injectors are an improved dual-stage design.  They provide better cold starts and less noise.  The AAZ pump has a camplate shaped to work with the 1.9 injectors and may not work as well with 1.6 single-stage injectors.