1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)

[8v-of-fury]

Ok so the front cover from the 1.6 pumps will work, as it is flat for the advance piston.

Also for using the tdi advance spring, cover..I must also use the tdi advance piston??

[libbydiesel]

Leave the inner spring and the upper idle lever.  Get rid of the lower cold start lever assembly.  One of the 1.6 front covers will work as a back cover, but longer term I'd be concerned about wear on the cover from the piston hitting it repeatedly.  You can't use the AHU back cover because it is held on with four bolts/holes and your pump only has two.  The Cummins pumps have a nice 1/4" thick steel plate.  Source or make one of those and you're in business.

Did you jump another spline w/ the accel lever yet?

[8v-of-fury]

The front cover should work without a doubt. It its still flat for the advance piston to slam against.

And what of the advance piston?? Is the tdi spring of lesser spring rate??

[8v-of-fury]

Check out my old 1.6 spring, half blue half green.. what the heck. What are the advantages of running the TDI spring, piston and cover? Is there more advance to be had with this setup?

[410]

Yes there is more advance with the tdi spring and cover.  The advance curve is also different.

[8v-of-fury]

Yes there is more advance with the tdi spring and cover.  The advance curve is also different.

While I have the pump off the car I might as well go ahead and swap in the TDI piston, spring and cover . Got a line on a couple of cheap pumps. One is an AAZ pump. M-tdi v2.0 will commence soon .

[CRSMP5]

if you need a scrap tdi pump.. i gots one.. all i know on it is it did not make fuel.. i did steal the injector line valves though.. no idea what shipping to canada is.. but id donate to ya for shipping costs if you interested..

[8v-of-fury]

if you need a scrap tdi pump.. i gots one.. all i know on it is it did not make fuel.. i did steal the injector line valves though.. no idea what shipping to canada is.. but id donate to ya for shipping costs if you interested..

PM'd buddy .

[8v-of-fury]

1.6 front plate on in place of the timing advance mechanism.



The AHU TDI front plate, advance piston and spring.



2 hours from that point everything was back together and running smooth. I had an issue with a leaking delivery valve that for some reason worked itself loose? Thought I got it tight enough when I had the pump off yesterday, but it still leaked when I got it back on. So instead of taking the pump back off and re timing, I frigged around for a half an hour trying to tighten that one delivery valve.. lmao. oh man hah.

Here is a quick question, can the 1.6 or 1.9 IDI delivery valves be used on the TDI head for DI operation? or are the valves DI and IDI specific?

[410]

The 1.9 idi valves are roughly the same length as the tdi ones so the hard lines fit okay but the 1.6 delivery valves are too short.  There is a difference between idi and tdi valves but jimfoo used the idi ones on his tdi with no issues. 

I suggest you use the tdi specific ones since you have them.  I read in my Bosch manual that they are different but I lent it to my buddy so I can't reference it right now.

[libbydiesel]

The shorter 1.6 valves are what fit the AHU lines (or at least they fit mine...).  The TDI delivery valves are different.  They have an added check valve in them.  I've personally used both 1.6 delivery valves and AHU delivery valves and have not been able to discern a difference in performance.

8V - did you jump another accel lever spline yet?   

[chopper03]

  I read in my Bosch manual

410, which bosch manual do you have and where can one be bought ?
                                                                         chopper

[410]

Hey chopper, I couldn't find it on the Bentley site but I did find it on amazon.  It's been a really good reference. 
http://www.amazon.com/Diesel-Engine-Management-Robert-Bosch-GmbH/dp/0470026898

[whoabeats]

I have that book in my truck right now. It is a must for any diesel head that wants to know as much as they can. I'll see if I can look up the info on idi vs di dv's tomorrow.

[8v-of-fury]

I suggest you use the tdi specific ones since you have them. 

The only reason I ask is because I have a few 1.6 distributor heads left over from two parts pumps.. and if the DV's will work I'll keep them around.

The shorter 1.6 valves are what fit the AHU lines (or at least they fit mine...).  The TDI delivery valves are different.  They have an added check valve in them.  I've personally used both 1.6 delivery valves and AHU delivery valves and have not been able to discern a difference in performance.

Ty Ty

8V - did you jump another accel lever spline yet?   

Not yet my good sir, my improvised exhaust is giving me some hassle.. so until I get that worked out (hopefully Saturday) the exhaust is pointing right at my firewall where my fuel lines run across.. So I can't be making too much exhaust heat just yet lol.

Thank-you for the advice on the advance mechanism, that woulda blown chunks to have come apart on the road somewhere..

I can already tell the splines will be the ticket.. just by removing the cold start advance and the fast idle being set all the way down allowed me to crank the fuel screw in another turn. A good chunk of power came from just doing that. I am still at this point further out than stock fuel screw settings. Fully shimmed GOVERNOR