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

[8v-of-fury]

The only problem I can see would be the using of the AHU pulley would require me to cut a hole in my timing cover to clear this..

The nut sticks out nearly 18mm.

[libbydiesel]

I'd get the ALH sprocket and hub but that's just me.  Are you sure you'd need to mod your timing cover?  Is yours an AHU cover?  It bumps out there.  How is that different from a stock AHU pump nut offset?

[8v-of-fury]

Good point, I guess it would stick out the same. Well then I would not have to modify the cover then.

However I do have an ALH hub available to me if I want it.. I do not have a pulley, nor do I even know where to obtain one without an ALH pump hanging off the back of it .

[libbydiesel]

There are several ALH sprockets without the hub on eBay or a wanted add on TDI club would get you lots of them.

[8v-of-fury]

So there is this guy, and he is a pretty happenin' dooood. He has been the biggest help with my very recent journey with the Bosch VE fuel injection systems, and I thank him 1000 times over. He is a member on this board, and he goes by the name of 410. He has helped immensely with my hurdles, and is THE MAN (sorry Lucas ) So here we have a 1Z TDI injection pump bracket, it has had its opening bored to ~68mm exactly (yes approximate exactness). It is pictured with an ALH pump, but they are the same size as the Rover snout. Pretty awesome right .

[8v-of-fury]

And the bracket arrived Tuesday, not too shabby for across the country in a day lol. With a perfect mirror finish on the snout-hole.. There will never be an issue twisting my pump ever again!



So as it would sit, I am just in need of getting my pumps mounting holes ob-longed to match the old style 1.6 and 1.9 pumps. Mind you the right pump in my picture is a 1.9L AHU TDI pump. And this bad boy is ready for some serious action. OH BOY.

[8v-of-fury]

Rover pump has been slotted and is awaiting installation first thing in the am!!

[RabbitJockey]

And???

[8v-of-fury]

And???

Annnddd I got that Rover pump on there... Timed it to 0.047" which is 1.2mm. Stock Rover settings caused it to start and runaway with a huge cloud of smoke. Well, they are what I assume to be stock rover settings.. the throttle stops all looked like they had been in that spot for a LONG time. and the fuel screw still has its collar. I indexed the throttle lever as well, so it all went back together perfectly the way I got it.

I had to back to fuel screw out like 5-6 full turns to have it not run away, and then it wouldn't idle. but taking it in some more would cause it to run away.

Its kinda cold, and im tired from last nights camping excursion lol so I didn't give it too much effort unfortunately..

I ended up putting a 9mm end cap on the head so I could use my M8 timing gauge, and I had to use 1.6 delivery valves over my AHU ones.. because I lost a very very very small piece from one of them.. They are the same internal style as the Rover valves I took out. The lines matched right up with no issue, and it timed up well with only one tooth more on the IP pulley over stock marks on the pulley.

I cannot think of what is going on inside the pump. When I can get it to run by holding the pedal, I have no throttle response.. but if I put in the fuel screw it runs away. I tried backing out the idle screw, but it didn't change anything drastically. I didn't want to go off all half cocked changing settings until I had some more time to think on the subject.

[libbydiesel]

Sounds like the accelerator shaft to lever orientation is wrong.  Go a couple notches clockwise with the shaft ccw with the lever.

[8v-of-fury]

Sounds like the accelerator shaft to lever orientation is wrong.  Go a couple notches clockwise with the shaft ccw with the lever.

It is possible that someone may have messed with it before I got it. I did re-install everything to exactly where it was when I took it apart. Seems like there is no way this pump would have run the engine it came off of.

[CRSMP5]

i had to turn my stops way in..... still not touched my fuel screw... but it would run away till i dropped my stop..

my idi dial gauge adapter fitted right into my 11mm tdi head/pump... you sure on the 9mm thing??

[8v-of-fury]

When you say you had to turn your stops way in?? You mean you had to increase the idle??

I had to back my max fuel out 6 Full turns to stop it running away. I also backed out the idle set to see if it would help but got nowhere near the adjustment. I will be removing the throttle arm and spring to test for governor cage compression and then set it there and try again.

[CRSMP5]

aka lower idle

[8v-of-fury]

Cannot get the pump to react well no matter where any of the settings are. How disheartening this is. LOL

I thought I had it good, but then I had no power under load. Well then I got the power there, but the idle was erratic and starting to hang between gears. And now I am frustrated.. as I spent over 2 and a half hours at every possible combination of settings it would seem.

Just for clarity, this pump has no back of the lid throttle adjustment. Just the two throttle stop screws and the max fuel screw is all. Nice and simply complicated.

I've had it at all different settings of throttle arm to throttle shaft orientation, however even the most relaxed setting of this relation is still not relaxed enough to need the fuel screw to be in as far as it was stock when I got it.