1.6TD pump building

[DA-BRT]

Hello,

As posted here earlier We are building a Frankenstein Fuelpump. We both studied Automotive technoligy in the Netherlands. We like diesel engines and VW.

We started of with a 1.6TD pumphousing.











10mm plunger/head (from a 1900TDI AHU)
Camplate with 3.3mm lift (from a 1900TD AAZ)
High pressure springs (from a 1900TDI AHU)
Advanced timing mechanism cover and spring (from a 1900TDI AHU)

We had a couple of problems while building it up.

We would like to use the camplate from the 1900TD AAZ because of the shape of the cam and the 1mm increased lift. But the problem was that the plungerhead didn't fitted in the camplate. I milled the plunger head from 20.3mm to 20.0mm. (same as the IDI plunger heads)

First I thought well go de easy way and use the Camplate from the 1900TDI AHU, but than we had problems between the camplate and spring on the main axle. When the roller bearings are not on a cam of the camplate the rollerbearings came loose.....

The IDI camplates don't have any material left between the two pins to propulse the camplate and the DI does got material there (see 3th picture for illustration) So I had to mill away material there from the camplate.

Becouse the 1900TD AAZ camplate has got my privelege I milled the plunger instead.

Now  we are that far that we can start building up the Govenor, Pump covers and on.

I've been searching for Torq values on the Bosch pumps, but I couldn't find them. Does anybody got a link where I can find Torq values for al the bolds and/or screws in and around the pump?

Greetings,

Bert

[X@V]

I'm building EXACTLY the same pump.

I used the '97 AAZ camplate (different from early 1.9TD's pumps) with the AAZ high pressure springs.

The only think I will need is the advanced timing mechanism cover and spring fron a ALH. Do you know where I could find it?

An other think, it's important tu use the AAZ throttle lever (this one that goes fron the top to botton of the pump)

 :wink:

[johnny]

There must be some guys out there who can help us out but it is also possible that we entered a top secret zone  :roll:

[Tintin]

A camplate of TDI that does not function in a mechanical pump with the speed lever and the control shaft of 1.6/1.9 TD,  that takes a speed lever of 4bt or 6bt cummins, and the control shaft in a fiat, Peugeot, or you makes it you same.

Another point, a TDI came plate is not adapted for an IDI engine, therefore if you envisage to put your pump on a 1.6/1.9TD, then the only solution for you is to find a pump (or came plate) of 1.9TD 1996 and up, and to put your 10mm at it.

If lived you in Europe, would have you the choice of several set-up of pump, but here one do not have the pumps which they have.

Martin.