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#105
by
jimfoo
on 28 Feb, 2008 10:57
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It looks like I will be getting some work done today as I think I have all the parts I need now. I got my new crank bolt and got my new nozzles as I had at least one bad one, and one injector put together wrong so that it had no pressure. Oops, I think it was the very first one I took apart, the different #3 injector. I thought I put it together the way it was, so maybe it was wrong to begin with. I will take them down to get tested, then some serious assembly will begin. Hopefully I will get it started today to make sure I didn't screw the pump up too badly. If I did, I may put it back together as an AAZ pump, then when I get the money, buy a core and have Giles work on it. My stocks are going back up quite a lot, so I may have more $ in the future for such things.
Look for more updates tonight. :twisted:
:evil: Well I had to leave the injectors there to probably pick up tomorrow. Sucks as it is almost a 100 mile drive. So all I felt like doing was cleaning other parts.
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#106
by
rallydiesel
on 29 Feb, 2008 16:05
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This is SOOOOO exciting! :oops:
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#107
by
jimfoo
on 01 Mar, 2008 19:41
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Ok some updates.
Got the timing belt on.
Pump on, injectors in and plowplugs in.
Things don't line up right using ALH lines.
From the back.
After lots of creative bending, everything plumbs up.
One other problem I had was timing the pump. For some reason I just can't figure out, I had to jump a tooth on the IP sprocket. So now my pump lock pin is no good when everything else is at TDC. I'm wondering if it might be from the TDI sprocket mod on the crankshaft.
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#108
by
jimfoo
on 02 Mar, 2008 11:13
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You guys are asleep, like I must have been. I'm surprised no one said anything about my tensioner being turned the wrong way. Luckily that.s what sleep is for, so your subconscious to tell the rest of your brain that you screwed up before it's too late. :lol: :lol: :lol:
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#109
by
rallydiesel
on 02 Mar, 2008 12:40
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So aside from the spring mods what did you do to get the pump tdi ready? A tdi pump head and a tdi camplate?
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#110
by
jimfoo
on 02 Mar, 2008 13:06
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Yes, a TDI camplate, 10mm head. And though I hear it won't work instead of changing the control lever, I put a thinner shim under the plunger foot so the bleed port won't open as early. But I worry it might wreck my idle, but there is only one way to find out. :lol: I will be ready to cover the intake with something other than my hand. I probably won't have the turbo plumbed to the intake for the first start either, but will restrict it's output so as not to overspeed it. I'm not positive the head is TDI as I don't know the difference between a TDI and IDI head. The way it is now though, the collar will come within thousandths of closing the bleed port at full throttle. I'm trying to get motivated to go work on it, but it was 70*F yesterday, and 6+" snow today and still coming down.
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#111
by
jimfoo
on 02 Mar, 2008 13:09
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If I do need to modify thr control lever, I got some pics from Tintin, and it doesn't look like it will be all that bad to do.
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#112
by
zukgod1
on 02 Mar, 2008 13:51
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But I worry it might wreck my idle, but there is only one way to find out. :lol:
I'm curious why you think your idle will be messed up.
Because of the cam plate?
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#113
by
jimfoo
on 02 Mar, 2008 13:54
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Because I moved the position of the plunger relative to the control collar. Maybe it won't. Maybe the governor will just adapt to the new setting, but I don't know as I couldn't find any info about how the shim affects things.
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#114
by
jimfoo
on 05 Mar, 2008 14:52
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I ended up having to re-bend a couple of the lines as they were in the way of the radiator hose. I also had to buy a new hose to go to the water pump since the TDI head has the bolts for the water outlet in a different orientation.
I also got the new rear seal on. It has been cold and snowy lately though, so between that and me bringing my adapter down to get some work done on it, I probably won't get much else done until Fri or Sat.
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#115
by
jimfoo
on 09 Mar, 2008 19:40
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IT LIVES!!!
http://www.66rover.com/TDIswap/TDI%20Parts%20121307/TDIstart.MOVThe timing seems too retarded even though I have it set at 1.01. I'm thinking having 220 bar injectors is retarding it some. It runs poorly without the advance solenoid energized, and does ok with it, but I'm sure it still needs more. When I first started it, it ran like complete crap, and sounded like it too. I could feel some air coming out the intake, and the intake was louder than the exhaust. I tool the valve cover off to verify timing, which was on, and noticed I could depress the lifters very easily, which I don't think you are supposed to be able to do. The ones I had in it were out of my first head. So I replaced all the squishy ones with ones from my newer but destroyed AAZ head. I started it up and it sounded way better but had a very high idle. I ended up having to re-index the throttle lever on the shaft and turn the fuel down as well. Even without the turbo hooked up, it seems to rev fairly well. I may take the timing cover off the pump and modify it for a little more timing at a later date, as well as adjust the fuel once I get it in the car.
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#116
by
rallydiesel
on 09 Mar, 2008 21:06
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You are a true scholar. I salute you.
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#117
by
zukgod1
on 10 Mar, 2008 00:51
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I love it when a plan comes together...
Good job.
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#118
by
jimfoo
on 10 Mar, 2008 01:04
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Of course, now I wonder how much power I will, or won't have without a modified control lever. Guess I'll find out... :lol:
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#119
by
Ziptar
on 10 Mar, 2008 05:29
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Absolutely Amazing! Nice work. You have blazed a new trail.