Club 80-90 Forums

I'm sure all this information is in here somewhere but the only definite answer I found was that the upgrade is easy and that the JX fuel pump is OK on the AAZ....

Just had a remanufactured 19TD AAZ from AW Engineering delivered to my mechanic to replace the broken (crankshaft pulley bolt snapped) 1.6JX in my '88 T25. Local diesel specialist (Bennett's in Watford) say that the JX fuel pump and injectors are different, but everyone else says that they will work in the AAZ.

My mechanic had the following questions to ask AW Engineering :

Do we reuse the following:
Water pump
Sump - I understand some sumps are too big.
Injectors - Are the fuels pressures OK?
Fuel pump (ours is 2 years old)
Turbo (2 years old again).
Glow plugs (new this year)
Radiator - is the standard one big enough?
Crankshaft pulley - ours is broken (the bolt sheared)
Gearbox adapter - do we need one?
Vacuum pump. We need new one - can you supply one?
Clutch - might at well put a new on ein, should we uprate it?)

to which they replied:

Yes you can reuse the following : water pump sump , injectors,fuel pump,turbo, glow plugs, radiator.
crankshaft pulley you will get a new one in the kit.
gearbox adapter - do you mean spiggot shaft bearing? if so yes.
vaccum pump -you get a new one in the kit
clutch - no dont upgrade but yes put a new one in

Does all this sound kosher?

Thanks,

Steve

I'm sure someone knowledgeable will be along to answer soon, can I ask what AW charged?

Sure - it's £1650+VAT for a bare 1.9TD, with a £400 surcharge until you return the old engine.

However, it's also about 12 hours work to do the swap. Stating to wonder if I shouldn't have gone down the 1.9TDi route from Ultimate Engineering for £4K all in for engine & gearbox fitted...

Steve

Anyone who says its OK to use JX pump and injectors on an AAZ doesn't know what they're talking about and shouldn't be trusted. Yes it will run but not as designed. If your mechanic has all those questions, frankly I doubt he's qualified to do the job !

There's loads of information been posted on this swap over the years here and on Brickyard. Use the search.

E D I T: See this http://www.brick-yard.co.uk/VehicleSpec ... ds/aaz.htm

I'd actually trust a mechanic who had questions about the details of the engine swap over one who say 'Just en engine, innit? Take one out, put one in." If you DON't know what you're doing, you don't know what to ask.

I saw the brickyard article but I've also seen lots of posts that imply the JX injectors, turbo and fuel pump are OK.

I've not seen any posts that explain WHY they won't work - my mechanic is suspicious because, (obviously) the AAZ is bigger and one would imaging that it'd need more fuel from the pump and injectors and possibly more/different boost.

Yes, the AAZ injectors will deliver the correct fuel for a 1.9, and are 2-stage also, not one as on the 1.6 JX. Yes you could fit JX bits and adjust the fuel screw, but you'd still have the poor JX LDA. A better option over the JX would be to use the 80hp GTD pump/injectors, some people seem happy with this. It does come down to personal preference really.

PS. Maybe my words were a bit strong, but I've previous experience of people having to ask questions and sort out issues on behalf of their fitters/'mechanics', which I don't think is right.

I think he knows his stuff - most of the garages use him. He's concerned with doing all the work to strip/clean/swap/rebuild the engines only for something to go catastrophically wrong due to insufficient/incorrect fuel delivery. If it works but is perhaps not ideal, then I can look to echainging my new JX pump and injectors at some point. What I don't want to do is damage the new engine.

The techie at AW engineering says he's done 'hundreds' of these conversion, reusing the JX turbo (I don't think anyone is disagreeing with this), fuel pump and injectors. I guess he would say that, but then again, why would he lie?

Steve

I know the Walsh's. I came across them a few years ago and first impressions were encouraging. I used them for a few parts/services a while ago, and TBH I wouldn't go back. They sell/use chinese components (to maximise their margins no doubt), and have an 'it'll do' approach. If I wanted a rebuild, I'd do my own, using my local engine shop for machine work and buying/fitting my own parts so I knew what was in there.

Can the aaz pump be used under an un modified engine cover? Sorry to jump on to someone's thread!

Bigjcc55 wrote:Can the aaz pump be used under an un modified engine cover? Sorry to jump on to someone's thread!

On a syncro yes...2wd it's very likely no...engine is lower in a syncro.

On a syncro yes...2wd it's very likely no...engine is lower in a syncro.[/quote]

So what is the solution? Can the engine be moved down in the 2wd?

If you use the BW throttle mod.kit you can get away with cutting away a small portion of the lid and then covering it with flat plate . The reason this is possible is because you gain back height from 1. The remodelled throttle arm and 2. The depth of the clearanced lid which is significant when you take into account the foam insulation and the depth of the ridges. Leaves you with a flat lid after. I cut mine with a router, makes a nice job of removing the foam - straight clean cuts to depth .