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Author Topic: IDI to TDI  (Read 47998 times)

Reply #105February 28, 2008, 10:57:43 am

jimfoo

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IDI to TDI
« Reply #105 on: February 28, 2008, 10:57:43 am »
It looks like I will be getting some work done today as I think I have all the parts I need now. I got my new crank bolt and got my new nozzles as I had at least one bad one, and one injector put together wrong so that it had no pressure. Oops, I think it was the very first one I took apart, the different #3 injector. I thought I put it together the way it was, so maybe it was wrong to begin with. I will take them down to get tested, then some serious assembly will begin. Hopefully I will get it started today to make sure I didn't screw the pump up too badly. If I did, I may put it back together as an AAZ pump, then when I get the money, buy a core and have Giles work on it. My stocks are going back up quite a lot, so I may have more $ in the future for such things.
Look for more updates tonight.  :twisted:

 :evil: Well I had to leave the injectors there to probably pick up tomorrow. Sucks as it is almost a 100 mile drive. So all I felt like doing was cleaning other parts.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #106February 29, 2008, 04:05:32 pm

rallydiesel

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IDI to TDI
« Reply #106 on: February 29, 2008, 04:05:32 pm »
This is SOOOOO exciting!  :oops:
2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"

Reply #107March 01, 2008, 07:41:57 pm

jimfoo

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IDI to TDI
« Reply #107 on: March 01, 2008, 07:41:57 pm »
Ok some updates.

Got the timing belt on.

Pump on, injectors in and plowplugs in.

Things don't line up right using ALH lines.

From the back.

After lots of creative bending, everything plumbs up.

One other problem I had was timing the pump. For some reason I just can't figure out, I had to jump a tooth on the IP sprocket. So now my pump lock pin is no good when everything else is at TDC. I'm wondering if it might be from the TDI sprocket mod on the crankshaft.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #108March 02, 2008, 11:13:15 am

jimfoo

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IDI to TDI
« Reply #108 on: March 02, 2008, 11:13:15 am »
You guys are asleep, like I must have been. I'm surprised no one said anything about my tensioner being turned the wrong way. Luckily that.s what sleep is for, so your subconscious to tell the rest of your brain that you screwed up before it's too late.  :lol:  :lol:  :lol:
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #109March 02, 2008, 12:40:13 pm

rallydiesel

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IDI to TDI
« Reply #109 on: March 02, 2008, 12:40:13 pm »
So aside from the spring mods what did you do to get the pump tdi ready? A tdi pump head and a tdi camplate?
2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"

Reply #110March 02, 2008, 01:06:49 pm

jimfoo

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IDI to TDI
« Reply #110 on: March 02, 2008, 01:06:49 pm »
Yes, a TDI camplate, 10mm head. And though I hear it won't work instead of changing the control lever, I put a thinner shim under the plunger foot so the bleed port won't open as early. But I worry it might wreck my idle, but there is only one way to find out. :lol:  I will be ready to cover the intake with something other than my hand. I probably won't have the turbo plumbed to the intake for the first start either, but will restrict it's output so as not to overspeed it. I'm not positive the head is TDI as I don't know the difference between a TDI and IDI head. The way it is now though, the collar will come within thousandths of closing the bleed port at full throttle. I'm trying to get motivated to go work on it, but it was 70*F yesterday, and 6+" snow today and still coming down.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #111March 02, 2008, 01:09:51 pm

jimfoo

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IDI to TDI
« Reply #111 on: March 02, 2008, 01:09:51 pm »
If I do need to modify thr control lever, I got some pics from Tintin, and it doesn't look like it will be all that bad to do.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #112March 02, 2008, 01:51:21 pm

zukgod1

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IDI to TDI
« Reply #112 on: March 02, 2008, 01:51:21 pm »
Quote from: "jimfoo"
But I worry it might wreck my idle, but there is only one way to find out. :lol:


I'm curious why you think your idle will be messed up.

Because of the cam plate?
dan

99 Golf TDI (now CNG powered) , 82 TD Caddy

Reply #113March 02, 2008, 01:54:31 pm

jimfoo

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« Reply #113 on: March 02, 2008, 01:54:31 pm »
Because I moved the position of the plunger relative to the control collar. Maybe it won't. Maybe the governor will just adapt to the new setting, but I don't know as I couldn't find any info about how the shim affects things.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #114March 05, 2008, 02:52:03 pm

jimfoo

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IDI to TDI
« Reply #114 on: March 05, 2008, 02:52:03 pm »

I ended up having to re-bend a couple of the lines as they were in the way of the radiator hose. I also had to buy a new hose to go to the water pump since the TDI head has the bolts for the water outlet in a different orientation.
I also got the new rear seal on. It has been cold and snowy lately though, so between that and me bringing my adapter down to get some work done on it, I probably won't get much else done until Fri or Sat.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #115March 09, 2008, 07:40:21 pm

jimfoo

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IDI to TDI
« Reply #115 on: March 09, 2008, 07:40:21 pm »
IT LIVES!!! http://www.66rover.com/TDIswap/TDI%20Parts%20121307/TDIstart.MOV
The timing seems too retarded even though I have it set at 1.01. I'm thinking having 220 bar injectors is retarding it some. It runs poorly without the advance solenoid energized, and does ok with it, but I'm sure it still needs more. When I first started it, it ran like complete crap, and sounded like it too. I could feel some air coming out the intake, and the intake was louder than the exhaust. I tool the valve cover off to verify timing, which was on, and noticed I could depress the lifters very easily, which I don't think you are supposed to be able to do. The ones I had in it were out of my first head. So I replaced all the squishy ones with ones from my newer but destroyed AAZ head. I started it up and it sounded way better but had a very high idle. I ended up having to re-index the throttle lever on the shaft and turn the fuel down as well. Even without the turbo hooked up, it seems to rev fairly well. I may take the timing cover off the pump and modify it for a little more timing at a later date, as well as adjust the fuel once I get it in the car.
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #116March 09, 2008, 09:06:29 pm

rallydiesel

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« Reply #116 on: March 09, 2008, 09:06:29 pm »
You are a true scholar. I salute you.

2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"

Reply #117March 10, 2008, 12:51:07 am

zukgod1

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« Reply #117 on: March 10, 2008, 12:51:07 am »
I love it when a plan comes together...

Good job.   :D
dan

99 Golf TDI (now CNG powered) , 82 TD Caddy

Reply #118March 10, 2008, 01:04:30 am

jimfoo

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IDI to TDI
« Reply #118 on: March 10, 2008, 01:04:30 am »
Of course, now I wonder how much power I will, or won't have without a modified control lever. Guess I'll find out... :lol:
Jim
1966 Land-Rover 88" with 1.9 1Z which has been transformed to an M-TDI
TFO35 mechanically controlled VNT, IC , and 2.5" exhaust.
Driven daily

Reply #119March 10, 2008, 05:29:14 am

Ziptar

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« Reply #119 on: March 10, 2008, 05:29:14 am »
Absolutely Amazing! Nice work. You have blazed a new trail.

 

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