Assembling Frankenpump. Any advice or suggestions?

[Karel87]

Hi there, this is my first post over here!
 I have an Audi 80 B3 with 1.9 1Y engine for a couple of years. It is a nice and simple car for cheap commuting and trailer pulling. Since it felt really sluggish compared to my gasser Toyota, I installed k14 turbocharger from AAZ engine and turned IP up a bit. It was a great improvement, but I want some more. 
Currently I´m running stock 1Y pump, which seems to be same as eco-pump (8mm plunger, 2,55mm lift camdisk, no LDA). I´ve bought an AAZ IP which turned out to be a bit leaking. So now I´m  resealing it. I have some different bits and pieces lying in the garage. Since I´m already opening that pump why not mix and match these pieces for better performance. 
My goal is 120-ish hp without affecting fuel economy. Current fuel consumption is about ~6,5L/100km (~40 US mpg)

I have:
1,6D N/A pump
1Y pump
older type AAZ pump with timing solenoid
1,6 TD pump casing with LDA
Toyota Carina E TD pump

Toyota IP has 10mm plunger. On my power level, would it have any benefit over stock 9mm? I mean like less smoke and EGT?
1,6 TD pump top seems to have better LDA, so i'm using that instead of AAZ one.
I'd like to get rid of that AAZ timing solenoid and replace it with 1,6D timing assembly. 1,6 pumps doesn´t have load dependant start of delivery. Should I use LDSD or not? Does it has any positive effect on power and efficiency or is it just for noise/NOx reduction?

I've researched for a while but this is still my first "frankenpump" so I look forward to any advice or suggestions.

greets, Karel

[bbob203]

I would send your box of parts to dieselme ken and have Him assemble something for you.

[Jetmugg]

No need to even send him parts.  Goran can source all the needed parts, and deliver a 100% ready to run pump that will exceed your expectations.

Steve

[Karel87]

Naah, I don't see any point spending that sum of money on a car with a market value less than a 1000 euros.   Fixing and modifying cars is more of hobby to me. Something which helps to get work and school out of my head. Paying someone else to do it takes all the fun part out of it. I have friend working in a diesel shop who is willing to calibrate this pump for me. Now i'm just thinking about which parts should i prefer when assembling my pump.

[libbydiesel]

Increasing HP WILL affect fuel economy.  If you play, you pay.

Install the AAZ camplate and 10mm plunger in the 1.6TD pump.  Use the 1.6 sprocket. 

[carrizog60]

Increasing HP WILL affect fuel economy.  If you play, you pay.

Install the AAZ camplate and 10mm plunger in the 1.6TD pump.  Use the 1.6 sprocket. 

all my cars(diesel) have better mileage when modded then it stock form.
driving normally that is

[libbydiesel]

driving normally that is

If you play, you pay.

[8v-of-fury]

driving normally that is

If you play, you pay.

Only when you play with that right foot

[Karel87]

After some reading and calculating i assembled my pump. I did use  10mm Toyota pump head with AAZ camdisk in a gtd housing. I sorted out softest advance spring and shortened advance piston  2,5mm to give some more dynamic advance. Newer style cold start lever with idle raising mechanism did not fit with older type timing piston, so i had to machine a spacer for compensating it.
I was eager to try it out so i did installed pump without calibrating. After bleeding it started straight up. It sure has some more kick compared to stock pump. 
On downside, as expected, engine really sounds a lot louder. Did try 0,92mm and 1,05 timing without noticable difference in sound. Compared to stock 8mm plunger, combustion process sounds really a lot more violent. Has anybody experimented  different timing with better results?  Sadly, my cold start lever with added spacer is interfering with pump bracket. Weather is getting cold here, so i had to swap it back to stock pump. Still have to figure out some better solution for it

[Blocksmith]

How about taking the static timing down even further? For having increased the dynamic advance, even .92 sounds a little on the higher end of things. From what I recall, Giles recommends around .85 for his pumps, though I have no idea just how much dynamic advance he puts in.

[RabbitJockey]

I agree maybe try back it off more.  Large plunger will also inject more fuel sooner

[8v-of-fury]

Truth, but usually with a larger plunger you need more static advance.

[RabbitJockey]

Truth, but usually with a larger plunger you need more static advance.

thats interesting

[carrizog60]

wouldnt that make noise be too loud?

[Blocksmith]

Truth, but usually with a larger plunger you need more static advance.

Really?    That's rather counter intuitive; how does that work?