[Vwdiesel] 1.9D pump install / injector hard line issues

[Roger Brown]

I am in the process of swapping in a nice Giles-rebuilt 1.9D pump (from a '90's vintage 
Passat 1.9D eco-diesel) into my '82 pickup which has been running a 1.6D pump for the last 
10 years.  So Giles set me up with the right offset drive sprocket.  But the issue I have 
run into is with the injector lines, actually 2 issues, pictured in the phota link below). 
  First the injector fittings on the 1.9D pump stick out about 40mm from the pump bod (red 
circle)y, about 20mm farther than the ones on the 1.6D pump, so the lines end up about 
20mm in from the end of the fittings.  Secondly, the top of the pump, where the TD boost 
aneroid would attach, hits the #1/#2 injector lines about half way in the adjustment 
rotation (green circle).  That is it is fine from full forward to straight up, but hit 
just past straight up and won't allow any timing adjustment past that point.
	http://www.4crawler.com/Photos/104_pana/p1040376.jpg

So is there a set of 1.9D or TD injector hard lines that would fit better?  If so, anyone 
have a VW part number or application for those?  Or, it would seem one could swap the 
shorter fittings from the old 1.6D pump onto the 1.9D pump to resolve the first issue, but 
still leaves the second issue.  Have since heard that the 1.9 pump output valves/fittings 
are specific to the larger pump, so swapping those parts from the 1.6 pump is not an option.

I do have an e-mail into Giles regarding this, but have not heard back yet.  Hoping 
someone here may have run into this and have a work around.

And what kind of hard lines are folks running with the 1.9TD (AAZ) engines?  I assume that 
combination is a similar setup.  I recall years ago hearing about having to bend some of 
the injector lines for the 1.9 engines.  Is this the situation that this applies to?

Thanks in advance for any insight folks have to offer.

-- 

   Roger