Please help 1.9 aaz engine in my samurai

[Fatmobile]

Wishing you no air in the lines.
If you see some for the first couple days it's normal.
The foam gets sent back to where the fuel gets picked up and it gets pulled back into the loop.

[vwtyp133]

Ummm... seems like it will be fairly easy to find TDC while he's got the head off. At that point it makes sense to do a pair of corresponding white paint marks on crank pulley & block, or bellhousing & flywheel peeking through timing hole (the standard Passat/Dasher/Quantum/Audi method) for re-alignment when the head is back on.

IIRC the "notched" head gaskets were for 1.5L IDI engines, while the HGs with "holes" were for 1.6L & later... or was it the other way around?

Pressure-testing a used VW diesel head, in my book, is always worth the typical $30. charged. If nothing else, it reassures one that any visible cracks are only benign 'surface issues', at least for now.

Good wishes; that 1.9L sounds like a nice match-up with the Samurai for economical off-roading,

J.R.
SoCal

[air-cooled or diesel]

well some of a problem; installed the clear lines. line from filter to inlet now has a big bubble by the filter, i cannt get it out, as i run it another bubble seems to come from the filter. only thing i can figure i should delete water separator, 30 yrs old so it prob is the prob(lem).

[Fatmobile]

The flow should be fast enough to remove any bubbles in that line.
Put a piece of clear line on the output of the pump and suck on it.
If fuel pulls easily through the pump; the "OUT" bolt isn't clogged and restricting flow through the pump.

I just had this problem with the 1.7TD Rabbit.
Fuel was moving but not fast enough to remove air from that line.
If you can't suck fuel through the pump; change the "OUT" bolt to a regular banjo bolt without the restrictor hole that allows pressure to built inside the pump.
Then try sucking fuel through the pump again.
Also try putting the line on the output of the filter and see how hard it is to suck fuel through the filter,.. you might want to try that first.
Fuel should move easily without having to suck hard.

[Samurai diesel]

Just an update guys, hired it out!! Overfilled the oil it ran away and bent the valves a little. Gonna be back in action soon fingers crossed!

[air-cooled or diesel]

yea well, im looking for an excuse to get a small vac pump for fuel sucking, one of the few things i need to round out my collection. not hoping to go back to my old ways of taste testing fuel, and having gas go all over my face. i put a restrictor on inlet, although the stock, supposedly clear, line is reduced, the restrictor is also an adapter. maybe too much of a restriction for fuel flow? its close to stock size, its injection tubing i cut down to a short piece and had to heat to get it on to inlet and also to 'clamp' on as it cooled.

[Fatmobile]

You put something on the front of the pump and you call it a restrictor.
Sounds like you are intentionally restricting the fuel supply.

Using a mity vac to pull fuel through the pump won't give you an idea of how hard it is to pull fuel through the pump.
If you can suck fuel through the pump, it doesn't take much vacuum.

Putting a piece of clear line on the output of the pump and sucking on it won't get you a face full of diesel.
Stop sucking when it gets close to your mouth.
It's not under pressure so it won't spray on you.

[air-cooled or diesel]

better word for it is reducer/adapter. as stock line is reduced from about 3/8 to fit inlet. i had a 3/8 line hooked up directly to pump and a fair amount more fuel was flowing thru.

[Fatmobile]

Oh, you had an electric fuel pump with 3/8" barb to reduce from.
How's the fuel pull test going?

[air-cooled or diesel]

How's the fuel pull test going?

yaa, the any testing wont help me any more,,the mainshaft seal blew, i have diesel around the ip pulley, will have to see if im going to reseal pump, getting it off is going to be the hardest part, as such things as the cold-start-pull doesnt come right off the pump, any links id be thankful for as per removal, re-install, gotta do some searching, and researching,pump had more than 750k miles, so no problem there, i now have to figure out if i want to fix her,,again. a/c i just had fixed went down, among other stuff, i dont know, right now
i was pondering a new block, is a new head and turbo, + id need turbo set-up, and stuff, well it can be fun if you actually do it,

[mtran]

How's the fuel pull test going?

any links id be thankful for as per removal, re-install

viewtopic.php?t=6694

[air-cooled or diesel]

thanks mtran, i think ive seen that from vwdiesel.net, is it still in faqs? i saw something that a bug had gotten to it,,im only resealing pump, i need to look for removal, and resealing pump, this pump has more than 750k mi on it may be getting up to 850k, i donno, clock stopped ~@700k, as it ends up when i first set the timing, i over tensioned belt, i let it loosen up,,a few weeks later is was over tight again,,was wining, dont know how it retightened tension,(could wet diesel shrink belt?) and soon the pump shaft seal,,went, i suppose if i had loosened tension earlier i could have gotten a few more miles out of seal,

[Fatmobile]

If you over-tensioned it and the seal now leaks,.. the bushing might be too worn too.
When the belt is loose grab the sprocket and see how much play it has.