Hello everybody. Let me first introduce myself as this is my first post on this forum.
I'm Sander, 30 years old, and a complete VW-nut. I live in a town called Beuningen in the Netherlands and own 2 VW's:
A '94 Vento (in US called jetta mk3), with originally a 1.8 90hp engine, and now converted to a G60 engine (3 years ago), with modded exhaust, G-charger (selft rebuilt and flowed) 68 pully, chip and FMIC. Should chuck out about 200 hp and 300 Nm of torque.
A '80 golf convertible mk1, originally a 1.5 gasser engine, converted first to 1.6 D, then converting that engine to a TD with IC and some pump mods (lda pin, governor spring mod, wastegate closed running @ 1.6 Bar). Now, after the head gasket blew (after giving a BMW 318TDS a very hard time till around 170 kmh and keeping the pedal down for about 25 km's straight) I've put in an AHU tdi engine from an mk3 golf.
Here is were the trouble starts. After reading a lot about m-tdi's on this forum, I decided to go for it, with help from my friend Bert, who is also on this forum sometimes. I would build in the TDI myself and he would build me a pump that would work with it.
So the way it is now: I have the AHU in, with original AHU nozzles, a rebuilt KKK K24 turbo, a 60 mm exhaust till the rear wheels, going into a 54 mm muffler for a TD mk1. The pump that Bert built for me is a hybrid from a 1.9 D (1Y) pump housing, governor, tension lever and governor lever assembly, the rollers, camdisc, the control sleeve and plunger assembly come from a tdi pump, the plunger is 11 mm. The current static timing is 1.10. The pumphead is of a 1.6 GTD (the 80 hp version) with LDA.
It starts up (without the glow plugs) at first turn of the key, runs smoothly through it's rpm's (no tacho, so don't know exact rpm's), and makes a normal diesel engine noise apart from the fact that it has a cone filter.
After starting to set the fuel screw (full load adjusting screw) and the residual fuel screw accordingly, the engine would develop more hp, untill I reached a point where the rpm's wouldn't go down smoothly after revving, this was after turning in the fuel screw 1/4 of a turn from the last (not so powerfull) setting. Now I turned the fuel screw bak in untill the revs would stop hanging, but then I have almost stock 1.9 D power. By turning it in a little more, the power increases, but certainly not to the same as it was with the 1.6 TD engine with upgrades. Now I have to shift very fast, to not have the engine hang in rpm's when shifting. When in 5th gear (4T type gearbox of a 1.6 GTD), going at a speed of 100 kmh and over, the rpm's come down real slow.
Now I've modded the pump with the governor spring mod, cutting out the intermediate spring, and I've put on a TDI advance timing spring cover and spring, I've also turned the star wheel on the LDA all the way down and the LDA pin is turned 180 degrees from it's original position. The governor mod made the rpm range a little bit longer, a little more hp (so it feels), and also al little wider powerband as for the torque. The advanced spring and cover swap just made it run a little more quiet. On changing the LDA spring load and turning the LDA pin it just seems to make a difference in low rpm's, torquewise. Now it makes about 1 Bar of boost at 140 kmh and over (3500 rpm and on). No IC yet.
I am sure (and so is Bert) that this engine should be able to make more hp with this pump, but we are just missing something. I've been searching a long time on this forum, but couldn't get the answer to the following questions, could any of you please help me with these?
1. I read everywhere that once the pump starts to hang in rpm's, you should turn the full load fuel screw back in, but just what is it that causes the hanging in rpm's? I can't imagine what it could be, because the control sleeve is mechanically forced back to stationary position, and that is the only way to raise the rpm's, or am I wrong?
2. Are there any others with a K24 on a AHU and what boost does it achieve?
3. Being in Europe, I can probably get my hands on all sorts of pumps to put on this engine. Could someone tell me what bosch pump codes to look for, on what engines they were supplied and how plug and play they are?
Sorry for writing such a terribly long story, I hope someone can get through it and maybe help me with my questions.
Thanks in advance,
Best Regards from Holland,
Sander aka Vento G60