Running a 1.6TD pump on a 1.9TD

[Baxter]

Below is a copy and past from another forum I just posted on.
The vehicle in question is a '89 VW T3, or a Vanagon if you prefer..

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Okay, just done a AAZ conversion for a customer, although this one didn't go as planned.

Customer supplied me an engine, and it came with the electronic timing control pump and no wiring.

I had a AAZ pump, so we were just going to throw that on.

Pump got damaged, so was scrap.

This left me in a bit of a pickle, customer wanted van back and I needed to get the conversion finished so i decided to try to run a 1.6 pump on a 1.9 engine.

After a bit of reading about cam plates and the like I came to the conclusion that the 1.6TD cam plate would work, but not as good as it could be, but the difference negligeable.

So, to put a 1.6TD pump on a 1.9TD engine....

The nose of the pumps are different, if you just try to bolt one up, it won't work, you need to use the 1.6TD pump, pulley and pump brackets.

The thin sheet metal timing cover from the 1.6 doesn't fit and the 1.9 one needs to be trimmed off above the brackets to make it fit and it cannot be mounted between the pump and brackets as it dispaces the pump and the belt won't run true, we know this as we tried, it doesn't work! so you also need to trim around the pump mounting.

You cannot use the JX style pump with the horizontal LDA as it fouls on the water outlet on the head, due to the block being that 19mm higher (or whatever it is)

You need the injector pipes from a 1.9 and also the delivery valves as they are matched to the injectors and are that little bit longer so everything bolts up without extra stress on the pipes.

Spec of the pump.

1.6TD "JX" pump with a upright LDA
JX throttle levers.
AAZ delivery valves

Once the pump is on, I timed it to .95mm lift at TDC.

After "One hours tinkering time" it runs really well, I didn't get the throttle levers on quite right the first time, and you would think that this should just make it run fast, but oh no, it's just a bit weird in all sorts of ways, soon rectified though.

Also, swapping between pumps means the residual fuel screw is in the wrong place, the one i did ended up with next to no fuel and would hardly rev, so, again in the hours messing, tinkering, knacling and bleading I got it right where it would rev and produce minimal smoke.

Turbo is KKK K14 "JX"

Inlet is a ported "JX" item, not strictly match ported as there is not enough material left on the manifold runner walls, I used a AAZ gasket as a guide, then marked about 1mm ish in to follow the stock line. I must stress that this is something I would not normally do as I like to match port but this engine has not been fitted for all out performance, just a customer wanting a little more grunt up the hills to replace his knackered JX.
The inlet manifold runner wall thicknes is acceptable, but I wouldn't want to go much further with it.

The owner will not be wanting to fit a intercooler and the like in the future, just wants a reliable van thats a bit quicker that his old one.

Doing the conversion this way means you can keep the JX airbox in it's stock position and the install looks very tidy (except for the wrongly wires split charge relay that was wired into the "W" terminal of the alternator!!)

I have only been around the block in it so far, with no engine cover on but it feels comparable to others I have done in stock form so fingers crossed.

My only concern is the 2 stage injectors and not running the cam plate to go with them, i suppose if it does cause problems I can always revert to the GTD or JX injectors that will be more suited to the 1.6TD cam plate, but we will just have to monitor that one..