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

[Bryan Belman]

Roger, where did you find this pump.  I have the same one on my 1.9NA motor now 
in the van, have been running this pump for about 1.5 years now.

I broke down and purchased new lines for #1 and #2. for the 1.9NA TD setup.  I 
was able to rebend #3 and #4 from my old 1.6NA stock of injector lines.
I do not have the part #'s handy but I bet I could look in my old files on a 
computer at home to find them.  VAGCAT, I would look up a 96 to get the part #s
This may work for you, log into vagcat first then hit this link.
http://www.vagcat.com/epc/cat/vw/POC/1996/165/49/1948039/
This is the injector pipes for the 1Y engine we have.  Seems like there are 
pipes for motors with AC and not.  I do not remember the L at the end of part # 
so I am guessing I ordered the pipes that ended in B.
10 028130301B   
pressure pipe
cylinder 1 / 
(10) 028130301L     
pressure pipe
cylinder 1 / air condit.: 1Y 
11 028130302B   
pressure pipe
cylinder 2 / 
(11) 028130302L     
pressure pipe
cylinder 2 / air condit.: 1Y  

I did not consider swapping the injector connector nipples as I call them, on 
the back of the pump.


 Bryan Belman, Pt. Pleasant, NJ
04 Jetta Wagon TDI PD, 100hp, 5sp -- running :<)
92 Jetta 1.6 Eco-Turbo Diesel, 5sp -- running :<)
82 Diesel Westy 1.9NA -- running :<)
70 Type 1 stock Elm Green Beetle -- Under Restoration :-) 




________________________________
From: Roger Brown <r.c.brown at ieee.org>
To: VW Diesel Fans <vwdiesel at vwfans.com>; Audi-VW-Diesels Group 
<Audi-VW-Diesels at yahoogroups.com>
Sent: Fri, April 22, 2011 12:16:04 PM
Subject: [Vwdiesel] 1.9D pump install / injector hard line issues

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
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