So really when you are elbows deep in an engine swap of this caliber, you do not have time to take pictures.. I only have these couple pictures to do anything with the actual swap.. Gasser mk1 passenger mount, new water pump and rear main. 200k km 210mm flywheel, hand freshened lol. Brand new 210mm sachs OEM clutch kit. To top of the tranny stuff a 1986 mk2 ACN transmission.
The night before I did the swap I drove my daily driver to the shop and hauled my pump off it and got a ride home with my brother. That night I dismantled my already franken-pump and made it an m-tdi one. It was a late 80's TD pump body, with a 91 NA lid on it. Of course fully shimmed governor and the fuel turned up as physically as high as it could go.. Any more and the idle got too high. I had the idle screws backed all the way out, and the throttle lever jumped back a spline so that more fuel screw could be turned in. I think even with the fully shimmed governor I was something like 3-4 full turns in from stock. Whhooooa! she flew for a non turbo lol. Sitting on my core support ready to go on the motor is a 1.6 TD pump body, with all the 1.9 AHU TDI internals, 1.6 lid and a mad whack boost pin by member 410 on here.
I drove it like this for about a month, and then when the weather got nice I decided to tear back in to it.. PLUS my modified throttle lever had been finished (also by member 410 on here) and was ready to be installed! Beside a stock one on the right, you can see that the ball end had been extended and the pivot hole in the side of the lever had been changed. Plus a few other key modifications like removing height from the lever so it would not hit the lid seeing as how it was being mounted sitting higher in the pump now. Modification to the LDA arm inside the pump lid had to be done as well. I have no pics of that, sorry. And the boost pin as well, on the right.
I had found a low low mileage 1.9AAZ pump body with zero main shaft play to use as my base for M-TDI Version 2.0. I had it totally apart and prettied up for when the lever got back to me
A little pump clearancing was needed in order to fit the newly modified throttle arm properly. A side by side of another nasty corroded pump, to see where the clearancing was needed for the new swing of the throttle arm.
All finished and buttoned up, on the car and running great.