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VW MKIII-A3/B4 TDIs This is a discussion about MKIII-A3/MkIII Jetta/Golf (<99.5) and B4 Passats (96,97) TDI's. Non TDI related postings will be moved or removed.

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Old August 10th, 2009, 11:03   #16
honda_vtec2
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Excellent article. Thanks Corrado and Chitty for the pic links.
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Old August 28th, 2009, 14:02   #17
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Quote:
Originally Posted by VW97JettaTDI
how do i get a hold of giles?
Giles' contact info - this guy can build a pump too. My 1.6 is stupid fast with his super pump on it. WOW!

http://www.performancediesel.ca/about.htm
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Old September 14th, 2009, 22:49   #18
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An update:
With an 11mm pump, a larger K03/K04 turbo boosting to around 20lbs, stock intercooler, PP520 injectors, TT downpipe and exhaust, and a factory JB ECU with the IQ set to about 5.4 the car runs quite well. I have yet to see any smoke from the tail during the day. When I leave work there's never anyone behind me to see what's there. I'm going to advance the timing a bit more and raise the IQ a bit and see what happens.
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Old September 15th, 2009, 01:13   #19
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Quote:
Originally Posted by tdibeliever
An update:
With an 11mm pump, a larger K03/K04 turbo boosting to around 20lbs, stock intercooler, PP520 injectors, TT downpipe and exhaust, and a factory JB ECU with the IQ set to about 5.4 the car runs quite well. I have yet to see any smoke from the tail during the day. When I leave work there's never anyone behind me to see what's there. I'm going to advance the timing a bit more and raise the IQ a bit and see what happens.
Hey sounds like you got a nice setup. Would it be possible for you to send me a log of your car with VCDS, groups 15, 11, 4 and 3. I'm doing some logging/tweak tests and would be nice to use your setup as a comparison. When you are WOT, do you have puffs of black smoke?.
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Old September 17th, 2009, 20:33   #20
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No puffs at all. I can get some data for you in the next day or two. I have to swap to the tuned ECU and get logs for Kerma as well. I guess I can do it all in the same morning. PM me your Email and I'll send 'em to you directly once I make them.
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Old September 18th, 2009, 10:18   #21
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Quote:
Originally Posted by tdibeliever
No puffs at all. I can get some data for you in the next day or two. I have to swap to the tuned ECU and get logs for Kerma as well. I guess I can do it all in the same morning. PM me your Email and I'll send 'em to you directly once I make them.
pm sent, thanks
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Old October 6th, 2009, 02:05   #22
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pump installed. Wasn't very fun going to the bolt shop twice. Guessing the lengths and all that. Timing the sprocket is SUPER sensitive. A bit of a frustration TB job, but it's fine.

-I blistered my fingers getting the electrical pins out, had a pin tool even, still not fun.
-The way the stock bolts go into the pump and through the brackets are opposite to the way I did it. I found my long bolts could not thread through the pump starting from driverside. (1z/ahu pumps are not threaded, alh is)

-I used a 1.5mm hardened washer for the shim. Bolt shop didn't have a 2mm. I tried 3mm but the shimming brought the sprocket WAY too close to the rear timing belt cover. Especially because the cover needed the washer and the clamp (top front which I removed the nut and put the bolt in) to be attached. If I didn't have to clamp down the rear cover, I would have been happy, but it stuck out too much.

-belt is tracking with maybe less than 1mm on the edge of the sprocket. Not my favorite place to be, but if I spaced it the 2mm, I would have been rubbing against the rear (sheetmetal) timing belt cover. Wierd.


These are the pieces I had to get other than the machined parts and the alh plug.

2 8x1.25 35mm hardened bolts (top front with a flanged nut and the bottom without a flanged nut (no way to get that on)
1 8x1.25 40mm hardened bolt (top rear with a flanged nut) longer because of the fender washer.
3 1.5mm hardened shims (the picture shows 3mm which I changed out)


1 fender washer with 3mm washer under it)to keep the rear timing belt cover (the sheet metal) from rattling. Tried two but the bottom one was rubbing against the sprocket.




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Old May 15th, 2010, 17:59   #23
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We did this for our Westfalia project, I'm running into a problem though. I have injector lines for the ALH and they don't seem to fit. Has anybody done this with ALH lines, if not does anybody have a set of AHU/1Z injector lines for sale ?

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Old May 15th, 2010, 21:38   #24
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You need AHU/1Z lines. Get them used because new they are $70-$100 each
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Old January 28th, 2011, 08:45   #25
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After learning about the AHH's injector pump being 11mm and the block being the same type of external waterpump block as the AHU I began poking around www.vagcat.com 's parts catalog. The injector pump's part number started with 038 just like a mk4 11m pump. This lead me to start looking at the cog gear, bracket and backing plate and these are all different part numbers.

The bracket: 028130147M
The gear: 028130111H 22 Euro
The Injector pump: 038130107J 2300 euro or 038130107JX 1105 euro most likely with a core charge

The site lists a different upper and lower timing belt cover but uses the same backing plate which has me a little puzzled. No matter as the backing plate and bracket are easy enough to have enlarged by a machinest.

The site also lists a different timing belt
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Old January 28th, 2011, 08:52   #26
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Fortunatly we have an AHH Passat in the USA with an enthusiast for an owner:
JFettig's Passat & pictures:







I'm betting that they used a wider belt to get a long enough belt life and all the cogs and associated parts are wider too.
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Old January 28th, 2011, 11:39   #27
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Looks tasty, thicker everything! What do you think Frank, 11mm pump on a 1Z, stick with the 60K TB changes?
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Old January 28th, 2011, 11:51   #28
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If I had an 11mm pump on a 1z/AHU I would drop down to 50k belt changes or switch to the wider belt setup.
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Old January 28th, 2011, 12:03   #29
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If I had only known about that AHH setup... Just wonder what the cost of the parts are. Hopefully it's not too bad being such a rare setup.
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Old January 28th, 2011, 16:19   #30
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Default ALH Injector Pump Swap Details from dieselgeek

Use www.7zap.com and look up the parts on the 1998 Passat. I used the site to look up parts for my turbo upgrade.
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