Mod 1.9TD pump with TDI Plunger?

[Duzty]

I am trying to mod a AAZ pump eith af TDI 10mm plunger an the cam from the TDI pump but i can't get it to run proberly!?

Has anyone done this before? Succesfully?  

What am I doing wrong?

[jimfoo]

You can't use the TDI camplate in an IDI, which is what it looks like you have by your sig. Put the IDI camplate in.

[Duzty]

We also tried only with the TDI plunger, and the AAZ cam, but the cam doesn't fit the plunger to good, so it won't pump any fuel.

[DA-BRT]

Make the plunger fit. From my head the IDI plunger is 20.3mm and the DI is 20.1mm or something like that.

[4KTD]

I had the same issue with my car. I put a 12mm pump head in my TDI and then took the 10mm and put it into my 1.6 pump... I found a guy who made some pins that fit into the IDI cam plate that it smaller on one side and larger on the other so the plunger is not loose. I also ground down the TDI plunger to make it fit inside the IDI camplate.  I also heard you can use a 1.9 IDI (1997-1998) camplate which can accept any TDI pump head and not screw up your timing.

[Benjamin]

with my very first swap i did this also, the tdi camplate is not good, just only use the tdi head&rotor, use the cam and the anti-return valves (internal) from the head from the stock td-pump.

i had the tdi cam running, but it was rubbish, sounds like the car was eating lots of metal and didnt stayed turning.

with swapping the camplate, beware the its not 180° off, otherwise you will have timing-belt-problems  :wink:    mark it very good so if you failure the assambly the first time you dont need to panic   :wink:

I always prefere to do the trail&error modus, but if you like to drive your car over working on it, you should better first read the forum and than do the workzz  :lol:  aah, also do some re-search, many guys including me have been spending time on this kind of problems.

Cheers, Benjamin

[gigaz2]

I just did this and the engine starts and idles ok, but has no power.

I swapped the 1.6 cam for a 1.9, then put the 10mm plunger (ground to fit).
the only thing I haven't swapped were the delivery valves, witch are the tdi ones.

I also shimmed the main spring on the governor, left the others stock.

[jimfoo]

So you have the TDI delivery valves in it, or the TD? You want the TD valves.

[gigaz2]

1.6 TD delivery valves in place, doesn't make a lot of difference.
albeit the valves themselves are really different!

also put a "max fuel" screw without the lock, that gave me more travel and adjustability.

still runs like a hammer is inside the engine... not very good signal, I guess I'll triple check the basic timing, might have a tooth off somewhere.

I really have to get a timing tool

[gigaz2]

another simptom: lots of smoke, even on idle.
if I try to lower the fuel, idle conditions worsen and stalls.
idle is unstable, goes up and down on its own. ~100rpm