AHF mechanical TDi injection pump conversion

[garooothos]

Hello
Im hoping you will be kind enough to help me or point me in the right direction.

I have a 1.9 ahf tdi engine with a vnt22 turbo and a 11mm head on the injection pump and larger race injector nozzles.

I would like to convert the pump from electric to mechanical (to make it easyer to fit into another car and avoid remapping the ecu) what do i need to do?

I do have 2 spare mechanical bosch injection pumps that came off a 1.9 peugeot 306/405

can i use these pumps? also what do i need to do regarding the turbo?

What sort of BHP can i expect to get from this set up? im not after much anything over 150 bhp would be fine.

Thanks

Gareth

[aidan]

If you only want 150bhp i'll buy the turbo and injectors off you. You'll make that power with the 11mm, .216s and a VA turbo.
As its stands, if you can control the VNT and if they are race520 injectors, you'd be looking at over 200bhp.

What year is the AHF? Its a hell of a lot easier and probably cheaper to get an afn engine loom and ecu than to adapt another pump to work and get the VNT working properly. You can almost run the engine loom standalone from the rest of the car wiring. I recently paid about €200 for an ecu that was custom remapped and had immobiliser removed.
Your Peugeot pumps are no good.

[garooothos]

Hi

Thanks for the help the ahf engine came from a 1999 Golf with a genuine 68000 miles on the clock it has been totally rebuilt as follows:
1.9 TDI engine code AHF 110bhp
Fully rebuilt head with 3angle valve seats and mild gas flowing
Modified pistons reducing CR to around 17:1
Lightened and balanced Golf G60 flywheel on new uprated Sachs VR6 clutch
Modified Allard intake manifold with custom EGR delete section
Modified exhaust manifold running GT22V turbo
Manifolds fully port matched
11mm injector head
injector rebuilt bu diesel bob wit uprated seals for bio diesel

the engine owes me a lot of money and i want to avoid buying many more bits for it and i dont think i will get anywhere near the money back i have spent on it. plus i really dont like all the electric ecu side of it and would prefer mechanical controls as it would make it easier to fit into the car im thinking of fitting it into (which will be 4wd so could take the extra power if i can get it easily)

What pump do i need to get hold of then? and what would be the best turbo to swap to? i still kind of want to get as much power as i can if its not too hard.

Im new to this level of tuning so need as much help as possible.

Cheers

[aidan]

Golf syncro?

There are a few pumps around that are 11mm, a couple of posts down they mention the land rover pump being near enough bolt on. There are others, Iveco 35-10 late 90s, LT 2.8TDI, maestro perkins prima, but often you'll find sprockets don't line up, governors are set lower etc. There will almost always be some kind of modification needed. You'll also have to find your own power level with your own tuning.
Unless the 11mm head in the pump is a chinese cheapo one, you'll get v good money for it though which will cover the cost of buying another.
You can run a VNT with a pressure actuator, not ideal as it'll always be running at max boost. Does the job though. Have a look at libbybaba's vnt mechanism, not something i'd use personally but apparently works.

[garooothos]

Rallye! maybe? depends how long the current engine will last!

I've know of one guy who has a tdi engine in his t25 camper and he has taken the electrical controls off his tdi pump and fitted the ones off the original 1.6 TD engine and made it work! or something like that. apparently a lot of people do this in the US and i was hoping to do something similar if i can find out how and what i need.

Any ideas?

[aidan]

Have a look at this http://www.vwdiesel.net/forum/index.php?topic=6427.0

Also have a look at items 190316058590 and 320387834444 on ebay. Unless you are pretty much a pump expert most people on here will say don't try and DIY a hybrid pump, then end result will be at best realistically only almost as good as a stock landrover pump or similar.
Look for some threads on here from oldskoolrich, he is using a land rover pump on a tdi

[gigaz2]

99% of people that do that are able to make it run. (1.6/1.9 pump with mods)

2% of those are able to make it almost as good as Etdis

so, take a good look at the schematics for the older tdis and you will be able to make a basic loom to fit on any car

[jtanguay]

99% of people that do that are able to make it run. (1.6/1.9 pump with mods)

2% of those are able to make it almost as good as Etdis

so, take a good look at the schematics for the older tdis and you will be able to make a basic loom to fit on any car

yea to make it run electronically you can use resistors in place of certain sensors.  if you get the immobilizer deleted, then its much easier.  and wiring diagrams are a must if you go this route.

[garooothos]

That looks like what im after i shall sit down a read it carefully! Thanks a lot for all your help

Does this mean that i my be able to use one of my peugeot pumps to modify my tdi one?

[aidan]

You probably could, but as mentioned it is unlikely it'll run as well as a proper pump. I would strongly suggest using another tdi pump aswell, that 11mm of yours is worth a fair bit now, and will be worthless if it goes wrong

[garooothos]

ok here goes! lets see if there is anyone interested in buying my engine and i can start again with a different engine!

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=290326820000

[aidan]

Did you buy this car from a bloke called Anton?

If so I think I sold him that turbo

[garooothos]

Yes i did! 

[aidan]

What engine you going to use instead? a 1.9td would be pretty rubbish compared to that

[garooothos]

Im open to suggestions! i would like over 150BHP and no ecu! any ideas anyone?