hello guys,
meanwhile, I realized the project, at least the pump.
As a base, I used a pump from a rover 200 2.0 TD engine (Bosch No.: 0460414118 - 20 mm main shaft and LDA - L-type). The high pressure parts and camplate came from a 2.5 l TDI pump (from ACV engine, Bosch No. will be delivered later).
Unfortunately, the inner parts of the rover pump were heavily corroded, therefore I had to purchase another IDI pump that came from a FIAT scudo (Bosch No.: 0460494370). I used almost all the IDI specific parts of the pump from the scudo (main shaft, lever assembly, upper housing incl. LDA, ...).
The upper housing of the scudo has the advantage of a mechanical shut down lever that works fine - so you don't need the shut down solenoid. Draw back is the fact, that this is a R-type pump and the throttle lever collides with the injectors - so, a tailored solution will be necessary in my vanagon, but this is no problem. For the test run, it has simply been cut.
The roller cage of the finished pump is from the TDI pump, but I had to remove the upper part of the cage to gain the space for the flyweight governor. Thats why it has only 4 rollers not 5.
Concerning the timing piston, I used the one from the rover pump - it was the shortest on (see pic - left: rover pump, right: ACV pump). The spring and the cover are from the TDI pump - this allows the highest travel of the piston (longest spring, highest cover). Additionally, I increased the length of the gap for the connecting pin in the rover main housing (just like the gap in the TDI housing).
The rover pump has got a solenoid for control of the timing. I did not activate it in the first tests and the engine sounded quiet good, therefore I believe that it won't be necessary to use this valve. I did some testing and setting up during this trial run but the real results will be gained on the road - unfortunately this will take some additional time.
You can find a video from the first test run on a 2,4 l IDI AAB engine (only for the test, the on in the vanagon will be an AEL) on youtube. I am not allowed to post the link, but you will find it by searching the following terms:
'Testlauf Bosch mTDI Einspritzpumpe 5-Zylinder' (27 s lasting)
PS: The AAB did not run for 6 month +; -1 °C; no use of glow plugs - preheating by hand-held heating gun; static timing at 0.95