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#90
by
Tintin
on 02 Feb, 2008 16:47
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I agree
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#91
by
jtanguay
on 02 Feb, 2008 18:26
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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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#92
by
jimfoo
on 10 Feb, 2008 23:08
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Been out of town for 3 days, so nothing yet as I just got home this evening.
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#93
by
jimfoo
on 13 Feb, 2008 19:31
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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.
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#94
by
lord_verminaard
on 14 Feb, 2008 10:08
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Ok, a few more pics. :twisted:
Picky no worky. :lol:
Brendan
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#95
by
jimfoo
on 14 Feb, 2008 12:05
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:oops: Oops, I made some changes to my website and forgot to update the pic links. All better now!
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#96
by
KTZed
on 14 Feb, 2008 12:29
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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.
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#97
by
jimfoo
on 14 Feb, 2008 13:44
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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.
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#98
by
burn_your_money
on 14 Feb, 2008 14:28
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that magnet is impressive in an unimpressive sort of way
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#99
by
jimfoo
on 16 Feb, 2008 21:01
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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.
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#100
by
jimfoo
on 16 Feb, 2008 21:29
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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.
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#101
by
subsonic
on 16 Feb, 2008 22:06
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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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#102
by
jimfoo
on 19 Feb, 2008 01:16
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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.
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#103
by
boxer246
on 20 Feb, 2008 11:31
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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
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#104
by
jimfoo
on 20 Feb, 2008 12:12
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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!!