Author Topic: IDI to TDI  (Read 43797 times)

Reply #90February 02, 2008, 04:47:49 pm

Tintin

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« Reply #90 on: February 02, 2008, 04:47:49 pm »
I agree

Reply #91February 02, 2008, 06:26:46 pm

jtanguay

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« Reply #91 on: February 02, 2008, 06:26:46 pm »
i can't wait to try my Giles pump!  out with the 1.6 lump and in with power/fuel economy  :twisted:


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Reply #92February 10, 2008, 11:08:36 pm

jimfoo

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« Reply #92 on: February 10, 2008, 11:08:36 pm »
Been out of town for 3 days, so nothing yet as I just got home this evening.
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #93February 13, 2008, 07:31:38 pm

jimfoo

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« Reply #93 on: February 13, 2008, 07:31:38 pm »
Ok, a few more pics.  :twisted:  


One piston in the block.

Just a pic of the bottom end with an oil squirter almost visible.

Oil pump and tray in place.

A pic of a magnet I had in the oil pan by the pickup. It is covered with loads of really fine metal, probably saving at least the oil pump.

What the magnet looks like clean.

The head sitting in place. It isn't bolted down yet, but soon... I also realized I ordered an AAZ gasket, but I don't think it should make any difference, though it's made to seal around the pre-chambers.
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #94February 14, 2008, 10:08:42 am

lord_verminaard

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« Reply #94 on: February 14, 2008, 10:08:42 am »
Quote from: "jimfoo"
Ok, a few more pics.  :twisted:  


Picky no worky.  :lol:

Brendan
81 Scirocco 'S -->Soon to be m-TDI
93 Corrado SLC VR6
'86 Golf N/A Diesel  -->Wife's car
1990 Audi CQ
05 New Beetle PD TDI


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Reply #95February 14, 2008, 12:05:23 pm

jimfoo

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« Reply #95 on: February 14, 2008, 12:05:23 pm »
:oops:  Oops, I  made some changes to my website and forgot to update the pic links. All better now!  :P
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #96February 14, 2008, 12:29:16 pm

KTZed

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« Reply #96 on: February 14, 2008, 12:29:16 pm »
Just a thought on the head gasket....youd have to do some calcs but considering how close the tolorances are with measuring piston protrusion and the diff thickness gaskets and all that, the extra volume created by the pre cup cutout might mess up the compression ratio. Then again the TDI's run lower comp anyways so maybe it wont matter. IMO It'd be worth it to do the calcs either way before you bolt 'er down.
'85 2d Golf + 1.6TD - Winter daily driver on the build
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Reply #97February 14, 2008, 01:44:27 pm

jimfoo

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« Reply #97 on: February 14, 2008, 01:44:27 pm »
There is no cutout, just embossing in different places. The hole is still the same as a TDI would have. I don't think it should cause problems.
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #98February 14, 2008, 02:28:04 pm

burn_your_money

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« Reply #98 on: February 14, 2008, 02:28:04 pm »
that magnet is impressive in an unimpressive sort of way
Tyler

Reply #99February 16, 2008, 09:01:27 pm

jimfoo

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« Reply #99 on: February 16, 2008, 09:01:27 pm »
Well, I decided to work on the IP today. I took the 9mm head off, put the 10 mm head on, swapped the check valves and end cap, put my intermediate spring back in, though stretched it a little for a little more tension, and shimmed the main spring a bit. I then decided to change the timing advance.  My pump was a little different than I expected though. Under the cover I found 2 springs, one inside the other. The smaller spring had 3 shims on the cover side, the larger only had one. I decided to remove all 3 smaller shims as the spring still rode on the larger springs shim rather than the cover. Then I decided to turn the pump over by hand to see how it worked. It doesn't. I guess that having the older AAZ pump, my cam plate has too much lift or is just plain too tall as it bottoms the plunger out on the head. Guess it's time to order parts.:evil:  Anyway, here are some new pics.







Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #100February 16, 2008, 09:29:51 pm

jimfoo

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« Reply #100 on: February 16, 2008, 09:29:51 pm »
It appears I have an older AAZ pump with the smaller plunger foot. They looked the same, but it is .03mm too small for the 10mm plunger foot.
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #101February 16, 2008, 10:06:54 pm

subsonic

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« Reply #101 on: February 16, 2008, 10:06:54 pm »
I just read on a tintin post that the older aaz pump was better for m-tdi pumps.  I think it was a post from today.
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Reply #102February 19, 2008, 01:16:03 am

jimfoo

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« Reply #102 on: February 19, 2008, 01:16:03 am »
Today I went to a diesel shop and got the boost pin and spring from a Cummins. The spring is shorter than the AAZ spring, but long enough. It is also much stiffer. The pin has the normal looking offset cone rather than the flat side like a regular AAZ pin. The best thing is that all the guy works on is VE pumps, he has lots of parts, and he can test injectors and pumps.
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily

Reply #103February 20, 2008, 11:31:06 am

boxer246

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« Reply #103 on: February 20, 2008, 11:31:06 am »
Jim,
Not to tell you something you probably already know, but if the pump doesnt turn maybe one of the cam rollers came out of position (ask me how I know)....pretty easy thing to happen when re-assembling the pump.  You should be OK with the 1.9 IDI cam and TDI pump head in terms of it not bottoming out.  But I will be really interested in what you end up with here.

 I am in the process of building a AHU m-TDI for my Vanagon.  Actually I just got the motor and am still pulling things apart getting ready for the rebuild.  I may have a bunch of questions for you if you can stand them1  :D
Ash
'81 VW Caddy 1.6 now a TD
'88 Vanagon (building a AHU M-TDI)

Reply #104February 20, 2008, 12:12:00 pm

jimfoo

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« Reply #104 on: February 20, 2008, 12:12:00 pm »
The problem is the plunger was too big to seat in the cam plate, so it was bottoming out as it was sticking out 2-3mm further than it should. I guess I wouldn't have had the problem with a later AAZ pump as they had the larger plunger foot to begin with.
I don't know how many questions I will be able to answer, but ask away!!
Jim
1966 Land-Rover 88" with 1.9 AAZ which has been transformed to an M-TDI
GT1749V, IC , and 2.5" exhaust.
Driven daily