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

[Roger Brown]

Thanks, Bryan.

Giles (http://www.performancediesel.ca/) found the pump for me up in Canada.  I think he 
had one sitting around his shop that he used as a core to rebuild for me.  I guess it is 
from an eco-diesel setup on the 1Y engine.

I'll check out those #1/#2 lines, those seem to be the main issue.  Looks like #1 line is 
bent to go behind #2 which looks like that will help with the top of the pump making 
contact as you rotate it for timing.


On 4/22/2011 9:59 AM, Bryan Belman wrote:
> 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_* <javascript:;>
>
> 	
> pressure pipe
> cylinder 1 /
> *(10)* 	*_028130301L_* <javascript:;>
>
> 	
> 	
> pressure pipe
> cylinder 1 / air condit.: 1Y
> *11* 	*_028130302B_* <javascript:;>
>
> 	
> pressure pipe
> cylinder 2 /
> *(11)* 	*_028130302L_* <javascript:;>
>
> 	
> 	
> 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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-- 

   Roger