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

[Roger Brown]

Thanks James;

It looks like similar parts are used on the 1Y and AAZ engines:
	http://www.vagcat.com/epc/cat/vw/GO/1995/159/49/1812151/

 From Bryan's info, p/n 028130301B for the #1 line on the 1Y and 028130301C for the AAZ.

So, heard one reply on the vwdiesel.net forum that said the 1.9 injectors were much much 
taller than the 1.6 injectors and the 1.9 lines (pressure pipes per VW jargon) may not 
work with the 1.6 injectors, as I assume this is what I have in my 1.9D engine.  Is the 
bending you describe the result of the injector height differences?  It does seem that a 
set of 1.9 injector pressure pipes would be a better starting point that to try re-bending 
the 1.6 lines I already have (of unknown age and condition).

Would there be any advantage to putting in a set of 1.9D (1Y) injectors in a 1Y engine? 
Or are the 1.6 injectors identical (non-turbo versions).  Seems like a good time to put in 
new injectors with the pump out of the way.  I know the mechanic that did the engine swap 
about 11-12 years ago and while he is very good he also is frugal and as long as a part is 
not broken, he'll re-use it.  Case in point is he re-used the old clutch 190mm when he put 
this new engine in.  He mentioned it had about 30% friction material remaining.  And 
within about a year or two, the new engine finished that off, so I put in a new 210mm 
clutch/flywheel/pressure plate and that works so much better.  So not sure what shape the 
injectors or hard lines were in back when they were installed and now they are 11-12 years 
older than that.  Will be replacing glow plugs for sure.


On 4/22/2011 10:04 PM, James Hansen wrote:
> You need lines from an A3 Jetta or golf Canadian version with the 1.9td.
> Pump had the same check valves as the one you are using, and it's a turbo
> setup, so there is plenty of top clearance as well.
> You can bend your lines, move the bend closer to the nut on the pump end,
> and put a wave in the line if you have too much, or move the bend away from
> the nut on the injector end. You have to take apart the four lines from the
> bundle and work with each one, it can be done. (I have done this on a
> different motor, tedious, hard to bend, but doable Roger.
> -james
>
> -----Original Message-----
> From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com] On
> Behalf Of Roger Brown
> Sent: April-22-11 10:16 AM
> To: VW Diesel Fans; Audi-VW-Diesels Group
> 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