Building an M-TDI pump

[snakemaster]

there is many ways to skin a cat as long as the end goods are the same , i have built a few pumps and tryed drifrant things in them , the pump on my mk2 golf has don 40th miles and if i sit at 55mph 65-70mpg and this pump is good for i would say 200hp but i de tuned to 130 so i dont brake anything so MTDI pumps can work just as well if not beter than Etdi, it shure starts beter from cold than the 14 etdi that i have had

[whoabeats]

(first Post)
I am also work on a basic pump build. I disassembled my vw 1.6 pump yesterday and all went well except for some of the screws I had to be very careful with and they will need replacing. The big problem was the jam nut and governor shaft were seized and that broke when it came out. So I went to boston fuel injection to get the replacement part and a rebuild kit. Waiting on a phone call from them now. Tomorrow I will begin to dismantle the ahu pump and organize my parts for the build. The plan for now is to start and run the engine for now with this basic pump and build my cummins pump down the road for more power. The reason for the hold off on the cummins pump mainly has to do with the need for a custom ip hub to mount an alh sprocket. Also I'd like to try a performance cummins governor spring (4200 rpm). Ideally I want fuel to higher rpms but the only way to run the vw govenor set up is to use the vw pump cover and throttle spring setup, and the springs on my vw pump are quite old and rusty.

[burn_your_money]

whoabeats, welcome aboard. How are you planning on mounting the 1.6 pump to the ALH? The housing is significantly different.

[whoabeats]

whoabeats, welcome aboard. How are you planning on mounting the 1.6 pump to the ALH? The housing is significantly different.

I actually have an ahu and it mounts up good unless I am missing something? The only thing alh I plan to use is the sprocket and that will be for when i build the cummins pump. At school I plan to machine a hub that will mate properly to the cummins snout and will bolt up to the alh's slotted holes. I believe it will be a very tight fit. I have yet to do any cad or design for it yet though because I do not currently have a alh sprocket.

[burn_your_money]

When you said ALH sprocket I assumed that you had an ALH engine. The AHU had either a 50mm or 62mm mounting diameter. The 1.6s were all 50mm (I hope I have those numbers right, it's been a while).

For the cummins pump, could you not just pop off the hub on the ALH and stick that onto the cummins shaft? They should have the same diameter shaft and the same taper. I don't know if the offset would be correct or not though.

[whoabeats]

This is something I have not attempted or found info for. That would be excellent if that is the case. I believe that the cummins pump snout is shorter though ( it is definitely shorter than the tdi and mechanical vw pumps I have now. I have to assume that the alh pump matches the others. All the B series engines which I am familiar with dont need to be as far forward because there is nothing between the pump and the gear as there is in a vw application, hence the shorter snout.

[8v-of-fury]

Whoabeats, WELCOME

I too was thinking of using the 1.6 pump as a stand-in on my TDI swap, so that I could get the motor in there with what I have and get it running.

I haven't actually had the opportunity to get my TDI pump off yet, (will tomorrow though) does the 1.6 pump line up with the AHU bracket?  

[whoabeats]

Thats excellent news, I have access at school to the whole machine shop minus the cnc machines. Which have just not been hooked up yet. But I could easily take a fly cutter and take off the dome face.

[carrizog60]

is it possible to swap the drive shaft so we could have the stronger shaft nose?

[whoabeats]

That is a good question my cummins and tdi are both 20mm shafts. If they are the same that would allow perfect alignment. 

[burn_your_money]

You can't swap the shafts because the TDI shaft does not have provisions for the gear that drives the flyweight assembly.

[carrizog60]

would it be hard to machine it?
that would end with the "rumors" of shaft being weak to a m-tdi install...

[burn_your_money]

would it be hard to machine it?

It's hardened steel (AFAIK) but if you have access to the tools I don't see why not. You would have to get the dimensions just right or the buffers wouldn't fit or one would be doing most of the work and would likely fail quickly.

[whoabeats]

would it be hard to machine it?
that would end with the "rumors" of shaft being weak to a m-tdi install...

Are you refering to machining the mainshaft snout? Because before I was told the alh hub would fit I planned to make my own hub for the cummins pump. I haven't been able to get my hands on an alh yet to try though. Once I have that hub though if it aligns. I'm ready to bench start it with the cummins pump. I'm gonna make a pressurized fuel tank via air compressor. And see how it runs.

[mdonau]

hi,

I am driving a Audi 80 from 1988 with a 1,9l mTDI.

I built my mTDI pump from a Citroen XM housing with 20mm axle where the housing and TDI T-Belt wheel fits direcly to the 1,9 TDI bracket.
on the "performance end" i used everything from a KIA Carnival 2,9 TD pump: plunger, camplate an lever
I took the timing advance parts and pumpcover /w LDA from an 1,6l IDI VW pump.
timed the pump at 0.9mm

At the start I used the SDI  nozzles from the AEY that was the base for this conversion, later i changed to 0.260 nozzles.
The original 228mm clutch cannot take the torque when the turbo starts making pressure (running at 1bar) around 1800 rpm!
At this time the car has gone aroung 80.000km with this engine without trouble.
Vmax is close to 200km/h at 4000 rpm, due to the nice FHN-code gearbox from an Audi A4 130HP PD-TDI.

I believe that with more boost the engine could deliver a lot more power, but it is enough for a daily driver (at the moment )
fuel economy is up to 20km/l !

greets, michael