AAZ to TDI?

[jasonsansfleece]

Mechanical was the OP's intent.

Setting power goals:
Short of being a mechanical engineer, or having the experience of several tested builds how do you know where you are going?
I have some idea of what I would like to do but what that amounts to? calculable? put it on a dyno and see?

[410]

I built my mtdi with an aaz block because that's what I had lying around.  I first built it with a k14 turbo and power was okay.  When I upgraded to a gt1749va turbo and intercooler power pretty much doubled.  I used the complete aaz bottom end, installed a tdi crank gear, and installed tdi pistons.  I then found an ahu head, valve cover, injectors, injector lines and delivery valves.  The injection pump was also from an aaz with 11mm head and tdi camplate along with some other mods. 

Power was amazing at a safe 20 psi with minimal smoke.  I would definitely build another mtdi out of an aaz block again.  As far as power goals I'd say 150-170 hp and 250ftlb of torque is totally reasonable. 

[lord_verminaard]

Which version of TDI piston did you use?

And you used stock AAZ rods?

Brendan

[410]

I cheaped out and used prothe alh pistons on the aaz rods.  The only issue I ran into was the top ring is a pinch higher on the alh pistons compared to the aaz pistons.  I was worried of the top ring braking when it would hit the ring grove in the cylinder so instead of boring to the next size I cheated and sanded the ring groove smooth in the top of the bore and lightly honed the cylinders.  Worked out really well and kept costs down in the end.  I would recommend used pistons with new rings instead of prothe pistons if your on a budget.  That's what I would do if I was to do it again.

[jasonsansfleece]

It seems quite feasible to build a m-tdi out of an azz.
How about the pump?
There is Giles of course but how about building your own and getting it to work properly?
A tdi head on a azz pump?
A Cummins 4bt pump?
Are there any pump build threads here or elsewere?
Ive done some searching here. A lot of older links are "404 not found" Is this info thats lost due to some system failure?
Thats a lot of question marks

[410]

It seems quite feasible to build a m-tdi out of an azz.
How about the pump?
There is Giles of course but how about building your own and getting it to work properly?
A tdi head on a azz pump?
A Cummins 4bt pump?
Are there any pump build threads here or elsewere?
Ive done some searching here. A lot of older links are "404 not found" Is this info thats lost due to some system failure?
Thats a lot of question marks

The aaz pump will run the mtdi setup.  It will start and idle well with an unmodified aaz pump but power is not great.  To get the full potential out of the mtdi the aaz pump can be modified to work very well. There is an excellent write up on building your own mtdi pump in the faq section.  The thread is now on page 2 of the fag section.  I would add a link here if I knew how.  Pay close attention to username Hey's posts as he describes in great detail of what needs to be done to build an awesome pump.  Here is how I see it;
-You can install a tdi head and rotor assembly to an aaz pump and run your mtdi reasonably well.
-Add a tdi camplate and things get better.
-Modify the control lever for extra travel and WOW!  Huge difference!
-Add the top from a 1.6td pump to simplify the fuel lever spring setup and a full functioning lda and now you have excellent smoke control and gives you a power band similar to a two stroke dirt bike.
-The timing setup on the aaz works well on an mtdi with very little adjustment.  
Cummins 4bt pump;
-I'm not sure what is involved as far as lining up the timing belt pulley.
-Install the top from a 1.6td pump with caged governor spring and your done.
Or spend some money and get Giles to build you one.

 

[jasonsansfleece]

Thanks 410
Did not think to look in the FAQ. Will read it tonight.
Did speak to Giles, he said he bores out an AZZ pump for a larger shaft (shaft failure due to loads involved pumping a large head?)
Anyway,

[R.O.R-2.0]

Thanks 410
Did not think to look in the FAQ. Will read it tonight.
Did speak to Giles, he said he bores out an AZZ pump for a larger shaft (shaft failure due to loads involved pumping a large head?)
Anyway,

plunger shaft or pump input shaft?

[410]

Giles bores out the pump for the larger 20mm input shaft.  There are lots of mtdi pumps running the smaller 17mm shaft which is what I did.

[R.O.R-2.0]

Giles bores out the pump for the larger 20mm input shaft.  There are lots of mtdi pumps running the smaller 17mm shaft which is what I did.

thats what i figured..

has anyone actually had a 17mm shaft fail on them?!

that would be a sight to see..

[burn_your_money]

has anyone actually had a 17mm shaft fail on them?!

that would be a sight to see..

Yes, quite a few times actually... I mean I have seen it

It is a sight

[blackdogvan]

has anyone actually had a 17mm shaft fail on them?!

that would be a sight to see..

Yes, quite a few times actually... I mean I have seen it

It is a sight

I was under the impression it was "ok" with a 10mm head but pushing your luck with 11mm. Tintin's pumps are usually 17mm IIRC.

[burn_your_money]

I think there are a lot more factors involved then just the size of the H&R, mainly how hard is that H&R working. You can crank up a 10mm to put out more fuel then a mild 11mm pump.