my aaz fuel pump mods not woking, need help, please

[oldskool rich]

recently i have rebuilt my pump with a 11mm pump piston and cam plate from a AFN to increase fuel pressure then changed to 1.6 injectors with merc 300td nozzles i timed the pump to perfection, however it wont run off the key :roll:

i got it started after towing it in 2nd for a while, it makes the worlds biggest amount of black smoke ever and is stupidly slow and sounds like a beetle.

i dont know what ive done wrong, in my mind it should be 200bhp+ with my other mods. does anyone know about this kind of stuff?

please help me b4 i just scrap the whole lot and go back to petrol :cry:

[jtanguay]

what are you timing it to? bring it to 1.00mm

[oldskool rich]

i dont know much about timing, what does 1.00mm meen?

first i lined up the whole in the pully with the one in the pump bracket then i loosend the pump off and then whilst it was ticking over i retarded it (pulled the top of the pump towards me as far as it wud go), it made no noticable difference apart from after reving it wud now idle instead of stall

then a few days ago i moved it a few notches hoping the engine wud fire up, but it didnt. i duno what to do, i cud spend the next month moving it notch by notch unless someone has a betta plan? :roll:

aparantly because im now running more pressure i might need an inline pump to feed the mechanical pump, or am i barking up the wrong tree? :oops:

trouble is where i live no one knows anything about diesels so i just hav to guess :cry:

[Vincent Waldon]

The fact that you are not sure what "1mm" means suggests you should probably grab the Bentley and read thru the timing section... for proper operation the cam, crank, and pump have to be in perfect harmony and it's not a matter of lining up marks... specific tools are required including a dial indicator.

If you haven't been thru the entire timing procedure it could easily be the source of your problems... I suggest starting back at the beginning, ensure all of the timing is perfect, and then see how she runs.

If you search here and at www.vwdieselparts.com you'll find tons of discussion on setting the engine up correctly from a timing perspective.

[vanagonturbo]

i dont know what ive done wrong, in my mind it should be 200bhp+ with my other mods. does anyone know about this kind of stuff?

What other mods? What kind of engine? AAZ? Where are you from?

[carrizog60]

search for a topic that i started regarding first time with timing tools.

you will see what you need and what to do

and yea, whats your setup for aiming 200hp?

[Black Smokin' Diesel]

You can't eyeball the timing on these engines. The pump is a very precise device and needs to be timed with a gauge. I tried eyeballing it and it never started.

[Tintin]

hoo boy!!   :lol:   .......   11mm head and AFN (TDI) came plate,  You built an M-TDI pump and put it on your IDI motor...  good luck!!

Replace your came plate by the TD one, and that will go much better, but not perfect, a 11mm request some adjustment.

[QuickTD]

hoo boy!!   :lol:   .......   11mm head and AFN (TDI) came plate,  You built an M-TDI pump and put it on your IDI motor...  good luck!!

Replace your came plate by the TD one, and that will go much better, but not perfect, a 11mm request some adjustment.

What he said...

Also, make sure the camplate isn't 180º out of time. The pin on the camplate should align with keyway in the pump shaft.

[oldskool rich]

well im only going by what ive seen from audi80's aaz scirocco wen i say 200hp, i dont meen to offend anyone, i cud be way off, he has a better turbo than me but hes only running a 1.6 head and dont think he has the merc nozzles, well tbh i havent spent nearly as much effort, i havent done studs, rods or anything just a t3 turbo running 30psi, 1z crank, gtd pump top, gov mod, 1.6 injectors, merc nozzles 11mm piston and afn plate, 3" straight through it hasnt cost me nothing really.

my mate stanton dynoed his gtd at 145 and just with my turbo running that much boost i could piss all over him untill the power ripped my pully off. so i hope to hit sumwhere round 200 now. i know it will fall apart at 200, i just want to dyno it then tune it down again.

will try with my old cam plate, and try to learn more about timing, although it was totaly perfect by sight b4 i put the engine in.

does anyone know where i can get the whole timing kit from (cheap)?

[jtanguay]

i know a Polish mechanic who can time these engines by ear.  he's probably done it maybe 200+ times though???  :wink: and even by ear he can't necessarily get it bang on.

imo its just easier getting the gauge and knowing its right the first time.  don't forget to turn the engine over a few turns and re-check at TDC.

the engine might hold up at 200 hp.  have you read andy2's thread?
http://vwdiesel.net/phpBB/viewtopic.php?t=2538&highlight=compound

he slightly bent his rods.   :shock: so he's running early PD engine rods which are holding up.  i don't think he's doing much on that project right now though.

don't give up now.  diesel is a whole different way of thinking than gasser.  to know everything is to know nothing, and vice versa... if that makes any sense  :lol: use that type of thinking, and you will learn by asking others on this forum.    but yes, firstly as stated above, get the bentley manual, and some timing tools.  

as Tintin said, you should switch back to the TD camplate as TDI's run MUCH higher pressures.

[oldskool rich]

just thort id check b4 i do it, last time i changed my pump piston and cam i had no special tools just an allen key, i here about all these special tools that cost loads of money
i dont realy see what there for, are they just to make life easyer or am i just doin sumthin wrong?
or are they to take apart the pully end of the pump?

[Tintin]

The solution with your problem is to reinstall the IDI came plate in your pump, because a TDI came plate does not work with IDI control lever inside your pump.

If not, you can find a specific DI lever, but on the whole you will have a M-TDI pump on an IDI motor, I am not certain that this is the best solution.

[Vincent Waldon]

Also highly recommended is to read up on setting the static timing with a dial indicator to measure plunger position

Eyeballing a diesel doesn't give you a particularly stable place to troubleshoot from.  It's a matter of thousandths of an inch, and you can't see the plunger to eyeball it ?

[oldskool rich]

The solution with your problem is to reinstall the IDI came plate in your pump, because a TDI came plate does not work with IDI control lever inside your pump.

If not, you can find a specific DI lever, but on the whole you will have a M-TDI pump on an IDI motor, I am not certain that this is the best solution.

what would you sugest to get the most power out of the aaz if not the piston pump?

ive heard people say that the standard pump can supply more than enough fuel, but im not so sure, i will be running about 30psi of boost with the softer injectors of the 1.6 and merc nozzels releasing more fuel. i cud be wrong, im fairly new to all this.

im gona change the cam plate tomoz if no one has any better ideas