10mm TDI head - fit it to AAZ or GTD pump?

[anto]

Why cant you interchange between 2 10mm plungers and collars?

They are matched pairs. It's something like a 2 micron difference between the 3 pieces. You might get lucky, but more often it will sieze, or not produce enough pressure.

Ah bollox that puts a spanner in the works of my pump rebuild.
I used the head and plunger from a spare 9mm pump i had because the originals were ruined, however, i had lost the collar for the spare head and plunger...doh!

I may get looking for that collar if its to work properly...

[regcheeseman]

You might want to install a 1.6td regulator and adjust it so that timing advance will be ok for all RPM.

Is that a straight forward swap? All AAZ pumps I have are fitted with the electronic advance do-hicky

As for part numbers, I've an eco sat here and

028 130 109 H (1y?)
028 130 081 A (AAZ?)
028 130 110 C (tdi)

also have a unknown nikki? pump

VE 4/10 F 2100R NP969 - origin unknown but it has a 10mm head.

[Helliouse]

@Hey
Please write up a quick tutorial on this, and have a moderator add this to the FAQ section.

Brad

[Runt]

I too would love to see some more detail from Hey, or from libbybapa. 

I recently fit the 10mm TDI plunger/head assembly into a pump using the late AAZ camplate and running it with single stage injectors.  The result was that I could not find a decent timing setting.  There was either way too much diesel knock or else too much smoke and hard cold starts.  I believe the reason is the extra machining on the plunger to accommodate the pilot injection event without using dual stage injectors.  Bad combo, IMO.  The inability to find a timing "sweet spot" was not readily apparent initially, but as I tweaked it more and more became obvious as a significant issue.

Did you solve this problem?  If you haven't tried it, do you think that using the AAZ two stage injector would resolve this issue?
And finally, is this same AAZ camplate/TDI plunger combination likely to work with an 11mm head?  AFAIK, the 10 and 11 are interchangable, so therefore everything should work, right?

[regcheeseman]

How do I differentiate between single and two stage injectors? Are they immediately obvious?

[GTD_MK2]

I've just built a pump like this

I fitted the TDI plunger/head into the 1.6 camplate (2.2mm stroke)
To make it fit i grinded down the diameter of the plunger foot to the size of the 9mm head (about 0,4mm smaller ) and modified the pin.
For this i put the plunger in a drill press(1 layer paper around to do no damage to the surface of the piston), let it spin and grinded it down with a angle grinder and a sand paper disc.

Noe the plunger foot fits in the camplate, but the piston has some slope to the pin, because in the tdi pump the pin diameter is 4mm, in the idi camplate the pin is 3.5mm.

So i smacked the pin out of the 1.6 camplate and welded 2 little points on the one end of it . After that i grinded them down so that its now exact 4mm wide.
Then i smacked the pin back in .

After this the assembly of the pump is just PnP, but you have to use the Delievery valves of the 1.6 pump head.

I just installed it on my car today(same time i changed the nozzles from DN0SD297, 280000miles on it to GTD nozzles (DN0SD274)) so i cant say if its the pump alone, but as far as i can say, the pump runs great, and it gives me a lot more fuel.
with the 9 mm head my fuel screw was screwed in as much as possible, now with the same pump and the 10mm head , i have the fuel screw 3 or 4 turns out and still got a bit more fuel than before.