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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: avocado on December 12, 2008, 01:59:07 am

Title: Um....where do the lines go?
Post by: avocado on December 12, 2008, 01:59:07 am

I'm nearing the end of my engine swap (AHU + MTDI into Zuki Sidekick) and I have come to the part where I need to hook up the fuel and air lines.....only problem is that I don't know where they go!

I have 4 lines between the injection pump and motor, three are fuel and one is air.  The fuel in line I know.  On the top of the IP, there is a small barbed fitting, I assume that is fuel return from the 4th injector?  If that is correct, where does my return to tank line go?  There is a fitting directly beneath my pump that looks like it should have a banjo fitting on it, but there is nothing there.  Maybe I am supposed to buy a banjo fitting and put it there for the return to tank line?

And then on the turbo side, I have two air lines.  One seems to go to the wastegate area......not sure where to route that one.  I assume it needs vacuum?  And the other is a line off of the pressure side of the turbo....I assmue that goes to the IP as a way to let the IP know to inject more fuel as boost increases?  Only problem is that I don't know where to put that either.......

Getting there......hopefully ready to turn the key soon.

Thanks for the help!

Title: Um....where do the lines go?
Post by: fairweather on December 12, 2008, 09:55:51 am

Depends on your IP but this is mine. The line goes from the pressure side of the turbo to the waste gate then tees off to the line you see in the pic, the left side line is for the boost gauge.
Also, the fuel line on the right is the supply from the filter and the left line is the return.
(http://www.mtsoprisventures.com/ip2.jpg)

Title: Um....where do the lines go?
Post by: avocado on December 12, 2008, 10:18:15 am

OK...that helps.  Thanks.

So the little banjo fitting on the top of the pump (flywheel side) is where the boost goes?

On my ALH car, the 4th injector goes back to the pump, is that the case with this pump too?  Maybe that 4th injector line does not need to return to the IP with this setup?

Title: Um....where do the lines go?
Post by: fairweather on December 12, 2008, 10:27:08 am

Here's another pic from the other side, it shows the return fuel line better. And yes the 4th inj line goes to the same banjo fitting that the return fuel line does (mine is a two nipple setup). you can just barely see the banjo fitting below right of the LDA right above the accel. cable. the banjo fitting on the LDA (right side) is where the boost line goes from the turbo.
(http://www.mtsoprisventures.com/ip1.jpg)

Title: Um....where do the lines go?
Post by: jtanguay on December 12, 2008, 10:36:02 am

Quote from: "avocado"

OK...that helps.  Thanks.

So the little banjo fitting on the top of the pump (flywheel side) is where the boost goes?

On my ALH car, the 4th injector goes back to the pump, is that the case with this pump too?  Maybe that 4th injector line does not need to return to the IP with this setup?

you definitely need the return from the 4th going to the injection pump.  more fuel fuel flows to the injector than is actually injected.  something would surely burst without them  :lol:

the banjo fitting on the top spaceship thing is for the boost, and just below that should be another out port for the return fuel (cloth line from 4th injector runs here too and then back to the filter, and then tank)

Title: Um....where do the lines go?
Post by: fairweather on December 12, 2008, 10:51:43 am

Here's with some labels, alot of lines coming and going.
(http://www.vanagonaccessories.com/ipdiagram.jpg)

Title: Um....where do the lines go?
Post by: avocado on December 12, 2008, 11:11:38 am

OH....that makes it clear!

My pump does not have any ports where you have it marked 'inj return' and 'fuel return.'  There is just a sleeve where there needs to be a banjo fitting with two barbs.....

Thanks!

Title: Um....where do the lines go?
Post by: dillenger1 on December 12, 2008, 11:09:56 pm

thats an lda from a mechanical pump,Do you have a stock tdi?

Title: Um....where do the lines go?
Post by: avocado on December 13, 2008, 01:55:57 am

The pump is a mechanical TDI pump....bought from Tintin.  Going onto an 1Z.

I just needed to add a banjo fitting onto that one port......now I should be good to go.

Title: Um....where do the lines go?
Post by: snakemaster on December 13, 2008, 01:55:45 pm

Quote from: "fairweather"

Here's with some labels, alot of lines coming and going.
(http://www.vanagonaccessories.com/ipdiagram.jpg)

fairweather what is that pump bace from dose it have a 20mm shaft as std

Title: Um....where do the lines go?
Post by: fairweather on December 13, 2008, 03:41:01 pm

It is a Cummins 4BT based pump, don't know the shaft size. You can get more info on it here:

www.westyventures.com
http://www.westyventures.com/bb/viewtopic.php?f=9&t=83

Title: Um....where do the lines go?
Post by: avocado on January 08, 2009, 11:15:28 pm

It has been up and running for a few weeks now....runs real strong!

As was recommended, I connected the wastegate line and turbo pressure line to the psi advance thing on the pump.  Do you think this setup is good enough to run?  The engine is stock, but I want to make sure that I am not overtaxing the turbo.  Any thoughts?  Should I just break down and get a boost gauge?