M TDI bus T3

[jeka2015]

Hello to all visitors of this forum from Donetsk, Ukraine) I apologize in advance for my spelling is probably wrong, because it is. speak English at the primary level, and use "Google Translator".
I am the owner of the van,VW Caravelle T3 1988, which was once stood 1.6td JX engine, it was decided to put him 1.9tdi 1Z. But due to the fact that in our territory now the war for a long time to deal with the electronics did not want to, and to be honest I do not like her, decided to collect motor on a mechanical pump that all could handle himself .On throughout the winter reading your forum, it was very hard to transfer, but something was clear, and the pump with a friend I gathered.
Now actually I need help, because such alterations in our services do not like all accustomed to the standard fuel pumps.I would like to define the terminology, which details how you call it, because we can not understand each other.
My mechanical pump assembled on the base of the housing 1.6td, it is worth the plunger, delivery valve, cam shaft, piston advancing from TDI pump, max fuel pin in the LDA, and even some modifications that will be apparent from photographs.
In general, the motor runs good, good traction, excellent start to hot and cold, but feels there is no 90hp.Unstable idling, inflated to the cold about 1100 rpm / min, and the hot engine 750-800 rpm/ min . Why he declines?0.9bar boost,no intercooler. As much as I twisted off the fuel supply, thick black smoke ... In general there is a lot of questions, I hope for your help, but a bit of everything, so we do not get confused))Thank)

[theman53]

Are you wanting more power?

[TylerDurden]

He's making a m-tdi...
It seems to not run well, with low power.

If I understand correctly:
He has a 1.9
The IP is an 1.6 housing; with plunger, delivery valve, cam shaft, advance-piston, boost pin in the LDA; all from TDI pump.
He's making 13psi (.9bar), but getting dark soot regardless of fuel screw position.
It idles poorly and 1100rpm cold, and 700-800rpm  hot.

He mentions IP modifications shown in pictures, but this message board may restrict images on new posts.

[jeka2015]

Are you wanting more power?

Yes, I want more power, I will suffice as an electronic TDI 90 hp.But how to do it ??

[theman53]

Did you do anything to the advance section? I would say at least using the spring and advance piston and caps from the TDI if you didn't already.

[jeka2015]

Did you do anything to the advance section? I would say at least using the spring and advance piston and caps from the TDI if you didn't already.

Do, now try to upload photos

[jeka2015]

He's making a m-tdi...
It seems to not run well, with low power.

If I understand correctly:
He has a 1.9
The IP is an 1.6 housing; with plunger, delivery valve, cam shaft, advance-piston, boost pin in the LDA; all from TDI pump.
He's making 13psi (.9bar), but getting dark soot regardless of fuel screw position.
It idles poorly and 1100rpm cold, and 700-800rpm  hot.

He mentions IP modifications shown in pictures, but this message board may restrict images on new posts.

Yes,I`m making mTdi.What is 1.9IP?Now try to upload photos not exactly my pump, and those parts that what we're doing.

[jeka2015]

Photos will upload each in a new report that it is clear from the description of the individual.
My friend is engaged in professional repairs fuel systems of diesel vehicles. When working on the pump properly used special tools, not a hammer)) Thus, the basis was taken the pump housing 1.6td, washed, cleaned to perfection, the body itself without working, in good condition. After the pump is assembled, it was put on the stand setup, but then there were difficulties with its setting, because the test plan for him there. But after this.

[jeka2015]

Photos of the internal parts, which we took from the pump 1Z, and have invested in housing 1.6JX

[jeka2015]

.

[jeka2015]

And most importantly, the axis of the gas with a fork, it's the only thing that we modified. And I probably guess here is our mistake. We did it in the following way, I saw it in the video instructions on Youtube. Link to the video can be attached. Photograph attached printskreen of video, photos of our axis of gas, I forgot to do (But do it at work, and looks like it is not as scary as the author of this idea

[theman53]

To me the front cap looks a bit short, but maybe not. I would check to see that you did use the front cap or swap a cap from a known TDI for the front. The rear makes a difference too, but if it came from a TDI it should be ok. If the advance is ok, then it probably is that gas fork as you call it.

[jeka2015]

It turned out something like this. Well, my max fuel pin. That's all the mods to the fuel pump. Ready to listen to what is wrong.

[jeka2015]

To me the front cap looks a bit short, but maybe not. I would check to see that you did use the front cap or swap a cap from a known TDI for the front. The rear makes a difference too, but if it came from a TDI it should be ok. If the advance is ok, then it probably is that gas fork as you call it.

Yes, the front and back cap of the piston advancing from TDI, it is 100%

[theman53]

With the pin ground like that I can see the smoke issue. Also, what turbo are you running? With smoke there is power or should be, so to me it seems like an advance issue, or a boost issue, or both. The pump is now over my head as to what to tell you to check.