The motor is a pretty fresh rebuilt 1.6 idi with a t-3. Just built an ip out of the original 17mm housing with enrichment, cam plate and 10mm pump out of an early A3 TDI with 20ish mm shaft. My timing tool no longer fits the pump, but i managed to set the timing @ 1.00 mm. The motor at idle sounds like its ping'in. It always sounded like it was detenting a little at idle, but now more so. I moved the pump all around, but can't seem to get it to stop. When it is set at .50mm the cold start (just timing, no idle up) lever makes a difference but it seem louder when out. The motor does have 480 ish compression, some generic euro nozzels. Why do some diesel ping more than other? My friend idi is quiet at idle. Maybe should of gone 3 notch head gasket?
The TDI camplate is likely the problem. IDI engines mix the fuel and air in the prechamber very quickly and promote very fast combustion. This fact, combined with the short and sharp injection ramp of the TDI camplate makes for lots of clatter.
IDI's like the fuel to be delivered more gradually than TDI engines. I would suggest using a newer style (larger plunger base hole) 1.9TD camplate with the 10mm head, probably make for a quieter and more powerful setup.
Did not realize using a cam plate from a the tdi would deliver the fuel to quickly. Don't have access to a 1.9td cam plate or pump. With the parts I have, should I reinstall original 1.6 cam plate and use the 10mm pump. I think the 10mm pump has the large plunger hole that u refer to. My timing tool know longer fits, it is to small. Any help or advice appreciated.
Parts on order... Any advice on timing still run 1 mm?
You can get a new 1.9TD camplate for $35 from Peter R. at
http://www.dieselvw.com/
In other post here, this guy is obstinated with saying that there is no 1.9TD cam plate with the large foot... Lololl...!!!!
I look at his part list and I do not find any.
But, If you need one, I have one in stock with big foot, It's a used bosh 35$ incl shipp, But It's the last one I have, make fast!!