Before the holidays, I took the plunge and had Giles do a "super pump" for me. I had a spare A1 TD pump, but Giles mentioned that a later pump would be better to start with. Big thanks to Tyler (burn_your_money) for hooking me up with a pump from a 91 or 92 Golf that had the mechanical fast idle and the residual fuel adjustment that Giles was looking for.
As a side note, Giles said that the last of the numbers on a Bosch pump indicates what "family" the pump is from. For example, this pump is marked 0 460 494 182, while the A1 pump is marked 0 460 494 064. Apparently the 182 is pretty common and he could do more with that one. I'm sure he has more insight on that.
Anyway, a few days ago, I got a nice present on my desk!
All clean and sparkly with new seals, washers and fittings... Here's the backside. You can see the adjustable fast idle mechanism.
I installed the pump a few days ago and everything fit just fine. I had a heck of a time getting the old injection sprocket off the pump in the car...even broke my homemade puller. With a friend we "remade" the puller with stronger arms that fit the pulley better and it finally came off.
Here it is at home in the caddy...
Results:
The engine now idles at around 850 rpm...around 100 or so less than it did before with the fuel turned up on the stock pump. Cold idle with the knob pulled out is just over 1100. Seems to help cold starting and warm up a bit.
Giles had me set the timing on this pump to .95 mm, but I think I might be slightly off on that right now. There's a bit of white smoke when I start it (more than the stock pump) and it seems to idle / start rough sometimes. I'm going to have to check that and follow up with Giles.
As far as performance, it's remarkable. I was saying to some friends that a Giles pump is the wake up call to a lazy engine...it's true.
First, the engine seems to have more power and less smoke off-boost and when it hits boost, it really pulls well. It's like lighting a fuse at around 8 psi...just rips all the way up to 18 psi. Giles built this one for 20 psi, but I haven't gone that far right now. I can't comment on what Giles did exactly, but he indicated that the pump can put out approximately 25% more fuel than the stock unit, a different boost pin and some LDA modifications. I'm sure the governor is modded too.
Along those lines, the biggest difference in the way this pump performs is in the upper rpm ranges. Before with the stock pump there was good power from 2200 to about 3800 before it kind of fell off / plateau'd in the boost. It was kind of like the engine "hit a wall".
Now, with the Giles pump, the engine wants to pull past 4600-4800 rpm and doesn't seem to fall off like it did before. I was a bit stunned to hear what the 1.6TD sounds like at that rpm..."frenetic" might be a good term.
Shift fast enough, keep on the boost and you run out of road!. Highway driving is equally nutty. At 70 mph, the engine is right around 3000 rpm and the turbo is on the boil. Lean on the pedal and it rockets up into the boost and it simply takes off. Way less smoke than before. I love it.
I thought the caddy was fun before, but this is definitely a step up.
As far as economy, I'll be able to report soon. I've only had it on there for around 150 miles.
This engine dyno'd at 102 hp / 142 ft/lbs of torque before this mod (with intercooler and GTD nozzles), so I'm anxious to see what it does now. I should be able to get it on the dyno as soon as I get it all tuned correctly. Great work, Giles!
Topic: Another Giles pump install (Read 7074 times)
