[Vwdiesel] [Audi-VW-Diesels] Re: 1.9D pump install / injector hard line issues

[Roger Brown]

On 4/25/2011 1:20 PM, Roger Brown wrote:
> Seems that Giles concurs with using the 1Y or AAZ injector pipes. So have a set of those
> on order, but will be a few weeks to see them as they are coming from the "mother land",
> so to speak. Also have a set of new 1Y injectors on order to drop in to the engine along
> with the new glow plugs and wiring for that.
>

The new injector pipes (hard lines) finally arrived from Germany on Friday.  Did a quick 
test fit and they do just screw with into place w/o an bending at all:
	http://www.4crawler.com/Photos/104_pana/p1040380.jpg
	http://www.4crawler.com/Photos/104_pana/p1040382.jpg
Here are the old 1.6 lines in comparison:
	http://www.4crawler.com/Photos/104_pana/p1040381.jpg
	http://www.4crawler.com/Photos/104_pana/p1040383.jpg

Looks like #3/#4 lines are pretty similar in shape between the two sets, but #1/#2 are way 
different.  Those reshaped lines allow the top of the pump to swing all the way forward 
for timing adjustment.  Have not compared the lengths between the two sets to see if there 
are any differences.  Have heard that those hard lines are apparently in short supply in 
Germany, not sure if VW will be having more made or not.

Do notice that it is required to re-wire the glow plugs with the 1.9 pump and the new 
lines as the pump and longer outlet valves+lines push parts right into contact with the 
glow plug bus bar.  So was planning to do that mod anyway, but now see that it is required 
to have separate wires to each plug.  Was unable to buy a set of the "real" 1.9D (1Y) 
injectors but did pick up a brand new set of 1.6D plugs (130 bar) to put in as well.  So 
have new Bosch Duraterm plugs and the new injectors to put in then on to the reassembly.

-- 

   Roger