1.6TD JX pump on AAZ engine

[Canadark]

Hey all,
We have a 1989 Syncro Tristar that came from the factory with a 1.6TD JX engine. A couple years ago the PO had a shop install a new AAZ long block using all the JX peripherals (pump, exhaust, intake, turbo, etc).

I'm working on getting it to run smoother. The beast smokes real bad at start-up and has loud diesel "nailing" Once warmed up it runs OK, but still very loud rattling and my milage is not what I'd expect (about 20mpg).
I have bought the necessary tools and checked the engine timing (good) and the pump timing ( at .99mm, .039in ) That timing seems good for the JX, but being on a AAZ block should I be timing for the AAZ ( about .80mm )??
I have also installed new air filter, new fuel filter, oil/filter change. No air in fuel lines.

From what I have read the symptoms indicate the timing being too advanced. What do you think? Should I time it closer to the AAZ at about .80mm?
Thanks!!

[mrhutch]

from what you said I suspect knocking the pump timing back a bit.. AAZ's had two stage injectors IIRC

[Canadark]

from what you said I suspect knocking the pump timing back a bit.. AAZ's had two stage injectors IIRC

As I understand the paperwork I got with the truck, it still has the JX injectors. How do I tell the difference?
I guess I might as well bump it back and see what happens. I admit I have newbee jitters about making it worse, my first diesel! It's been an interesting learning curve just getting to this point.

Here is a photo of the engine bay:

http://images.thesamba.com/vw/gallery/pix/1148361.jpg" onclick="window.open(this.href);return false;

[Canadark]

I was hoping someone could tell me definitely whether the pump timing is set to the pump type (1.6TD JX) or to the engine (1.9TD AAZ)?

I have backed the pump up to .96mm and it seems a little quieter, still just as smoky. Adjusting the IP was easier than I thought it would be. The only real fun was rotating the engine. I can't access the crank bolt (muffler in the way) so I jacked up the passenger side rear wheel and leaving it in fourth gear rotated the wheel to move the engine. A little bit fusty, but worked.

Still very concerned about the loud engine noises. It is a new long block (per receipts) so the internal bits should match properly.
Maybe bad injectors? (original JX), or worn pump?

If I can ever figure how to post videos maybe a movie will help.

Here is a link to my post on theSamba:

http://www.thesamba.com/vw/forum/viewto ... hlight=aaz" onclick="window.open(this.href);return false;

[max and caddy]

The JX is never a quiet engine...some noise is a good thing...smoke may be down to duff injectors or turbo...or even oil quantity...the more advance the more the noise but less smoke generally....smoke is more prevalent with a retarded injection angle.

[chrisbeck]

Sounds like a timing issue mate. I might be wrong here but i seem to remember that when you put the jx flywheel on the aaz crank the TDC mark ends up in a different place, if i am right and you havent re indexed the flywheel you will think its timed up properly but it will be out.
Mine was out by one tooth on the cam belt, and it did all the things you are describing, sorted out the timing and it has been perfect since.
Sorry if it turns out that i am talking out of my a***, perhaps someone on here can confirm or rubbish what i have just said.