AAZ conversion issue with revving the engine

[mattyboi85]

Today I fired up my AAZ conversion for the first time in my son's T3 twin crewcab van. The engine runs but I have an issue with revving the engine. If you presss the accelerator to the floor you have about 1" of movement of the throttle lever on the pump. With full throttle the engine revs hardly changed.

As a test I wound back the screw on the body that acts as an end stop for the throttle and find I have to turn the lever on the pump past the end stop to get the engine to rev up. I bought the engine including the pump from a scrapyard so never had it running before the conversion. The only thing I have done to the pump is remove the second spring above the first and added the "Baxter" lever. Is it possible that I have some how upset the position of the spindle in the pump which is causing this problem ?

I really would appreciate some advice on this as at the moment I cannot move the van until I understand and fix this issue.

[caveman]

By moving the throttle [it actually is the govenor, but lets not fight over names just to complicate things ],arm on the pump,you just probably moved the new arm too far one way or another. Look at the lever/shaft location. Remove the nut. Maybe make a small mark so that you can understand it's position. Back off the idle stop screw so it won't interfere with the lever when you relocate it. I would think you want to move it one spline further away [move it towards the back of the truck]. reinstall screw, adjust idle screw until it touches the lever and turn it another full turn. before attaching the throttle cable start the motor and try it. If it now revs higher, adjust the idle as best possible for now. attach the throttle cable, adjust accordingly. take it for a spin and see. You may have to play with it a couple of times to get it right. Also if the engine sat for a long time without running it may need a few miles to get out all the crappy crap that was in the pump and injectors before it's running 100 %

[mattyboi85]

Thanks for your help. I adjusted the positition of the centre screw and the engine now revs up OK with the accelerator pedal.

I have a leaking sump windage gasket plus one other oil leak to sort and we will be back on the road after a 5 month layoff. Working on van engines outside over the last few months in the cold is an experience I do not want to repeat. Just glad the engine fired up yesterday without too many issues.

[caveman]

Cold?
On the past friday i was working on my friend's Jetta TDI for about 45 minutes. We waited until the sun was up for a couple of hours to warm things up. It got up to a balmy -3 o F

[mattyboi85]

I have been doing that for at least the last two months. Waiting for the sun to warm up and going into the house every half an hour to thaw out my hands. I must be a glutton for punishment. It is all worth while once the engine starts, all previous hardships pale into insignificance. Roll on summer and attending various VW events.