With the current rainfall situation the paint's on hold so I'm getting on with the motor, more specifcally the injection pump.
I was up until nearly 3am building it last night, basically it's a late AAZ (rubbish spec) pump body with a TDI pump head.
The TDI pump head is only a 10 mm one - thanks to a lying git of an ebay seller 'sorry did I say 11, oh I meant 10, does it matter?
?' -
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I'm using the AAZ camplate to keep the TD fuel profile. It took several goes to get the pump head on without a component falling out of place before getting the head in place, but finally I got it fitted
before realising I hadn't swapped the o-ring seal for a new one
- the pump was fine with no leaks previously, but sods law say's it'll leak unless I change it, so I had to take the pump head off again. Seal swapped and it went back on easily, as I had had some practice by this point!
There's a accelerator limit plate on the late AAZ - that was binned
The GOV got modded and the main spring swapped for one stronger than the weedy AAZ one - think I swapping in a 1.6 or a early AAZ/1Z spring
Fitting the LDA up (after spending 40 min's trying to find the 2 LDA diaphragms that I had carefully stored months ago) and I noticed that even on full accelerator the LDA pin wasn't even coming into play and that the external accelerator lever stop was set well short of max; a quick fiddle and the LDA is pin is now visible when max accelarator pedal is used.
When I got the pump the pulley was loose - so I didn't know where to refit it.
Am I correct that port A is injector 1 and that the key slot in the pump nose is aligned with the port A when the pump is locked up. i.e the woodruff key slot roughly matches the port that is currently being used by the pump head?
As per some excellent advice on here
I'm going to set up the pre lift at 1.15mm as a base setting. and this is where more fun and games began....
My DTI adaptor was too small 7mm adaptor - 8mm pump head fitting, so I checked my tool catalogue for another adaptor, then realised that the injection sensor I need to use also doesn't fit, could I swap the fitting in the centre of the pump? The 3 faced, specialist tools required one! - there's no tool available in my catalogues???
I dug through my spanners and nothing fits, I then tried my weird spanners box and found an old 9/16 whitworth fits just fine, (not a regular spanner in the all metric UK - thankfully I was brought up on triumph motorbikes and inherited a selection of old tools)
I had to remove the port valves to get access but the fitting was a straight swap for one from and old 1.6 TD pump. Hurrah!
Interestingly I noted that the TDI camplate seems identical to the AAZ one, I only had a quick look but the lift seemed similar, very similar to a GTD one, however the 1.6TD one I also have is pitiful in comparision.
I've now got to start on the cosmetics and get it looking worthy of my engine bay, but it shouldn't be far away from getting a cam belt on my motor....mind you the sun is out and I need to paint before winter hits....
Topic: Hybrid pump build in the small hours (Read 2258 times)
