Assembling Frankenpump. Any advice or suggestions? - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Assembling Frankenpump. Any advice or suggestions? by Karel87 on 24 Sep, 2013 01:41
• Hi there, this is my first post over here!
   I have an Audi 80 B3 with 1.9 1Y engine for a couple of years. It is a nice and simple car for cheap commuting and trailer pulling. Since it felt really sluggish compared to my gasser Toyota, I installed k14 turbocharger from AAZ engine and turned IP up a bit. It was a great improvement, but I want some more. 
  Currently I´m running stock 1Y pump, which seems to be same as eco-pump (8mm plunger, 2,55mm lift camdisk, no LDA). I´ve bought an AAZ IP which turned out to be a bit leaking. So now I´m  resealing it. I have some different bits and pieces lying in the garage. Since I´m already opening that pump why not mix and match these pieces for better performance. 
  My goal is 120-ish hp without affecting fuel economy. Current fuel consumption is about ~6,5L/100km (~40 US mpg)
  
  I have:
  1,6D N/A pump
  1Y pump
  older type AAZ pump with timing solenoid
  1,6 TD pump casing with LDA
  Toyota Carina E TD pump
  
  Toyota IP has 10mm plunger. On my power level, would it have any benefit over stock 9mm? I mean like less smoke and EGT?
  1,6 TD pump top seems to have better LDA, so i'm using that instead of AAZ one.
  I'd like to get rid of that AAZ timing solenoid and replace it with 1,6D timing assembly. 1,6 pumps doesn´t have load dependant start of delivery. Should I use LDSD or not? Does it has any positive effect on power and efficiency or is it just for noise/NOx reduction?
  
  I've researched for a while but this is still my first "frankenpump" so I look forward to any advice or suggestions.
  
  greets, Karel
• #1 by bbob203 on 24 Sep, 2013 05:01
• I would send your box of parts to dieselme ken and have Him assemble something for you.
• #2 by Jetmugg on 24 Sep, 2013 07:00
• No need to even send him parts.  Goran can source all the needed parts, and deliver a 100% ready to run pump that will exceed your expectations.
  
  Steve
• #3 by Karel87 on 24 Sep, 2013 10:55
• Naah, I don't see any point spending that sum of money on a car with a market value less than a 1000 euros.   Fixing and modifying cars is more of hobby to me. Something which helps to get work and school out of my head. Paying someone else to do it takes all the fun part out of it. I have friend working in a diesel shop who is willing to calibrate this pump for me. Now i'm just thinking about which parts should i prefer when assembling my pump.
  
• #4 by libbydiesel on 25 Sep, 2013 07:50
• Increasing HP WILL affect fuel economy.  If you play, you pay.
  
  Install the AAZ camplate and 10mm plunger in the 1.6TD pump.  Use the 1.6 sprocket. 
• #5 by carrizog60 on 25 Sep, 2013 14:06
• Quote from: libbydiesel on 25 Sep, 2013 07:50

  Increasing HP WILL affect fuel economy.  If you play, you pay.
  
  Install the AAZ camplate and 10mm plunger in the 1.6TD pump.  Use the 1.6 sprocket. 
  

  
  all my cars(diesel) have better mileage when modded then it stock form.
  driving normally that is
• #6 by libbydiesel on 25 Sep, 2013 14:36
• Quote from: carrizog60 on 25 Sep, 2013 14:06

  driving normally that is
  

  
  

  Quote from: libbydiesel on 25 Sep, 2013 07:50

  If you play, you pay.
• #7 by 8v-of-fury on 25 Sep, 2013 17:36
• Quote from: libbydiesel on 25 Sep, 2013 14:36

  Quote from: carrizog60 on 25 Sep, 2013 14:06

  driving normally that is
  

  
  

  Quote from: libbydiesel on 25 Sep, 2013 07:50

  If you play, you pay.

  
  Only when you play with that right foot
• #8 by Karel87 on 02 Oct, 2013 13:36
• After some reading and calculating i assembled my pump. I did use  10mm Toyota pump head with AAZ camdisk in a gtd housing. I sorted out softest advance spring and shortened advance piston  2,5mm to give some more dynamic advance. Newer style cold start lever with idle raising mechanism did not fit with older type timing piston, so i had to machine a spacer for compensating it.
  I was eager to try it out so i did installed pump without calibrating. After bleeding it started straight up. It sure has some more kick compared to stock pump. 
  On downside, as expected, engine really sounds a lot louder. Did try 0,92mm and 1,05 timing without noticable difference in sound. Compared to stock 8mm plunger, combustion process sounds really a lot more violent. Has anybody experimented  different timing with better results?  Sadly, my cold start lever with added spacer is interfering with pump bracket. Weather is getting cold here, so i had to swap it back to stock pump. Still have to figure out some better solution for it
• #9 by Blocksmith on 03 Oct, 2013 19:14
• How about taking the static timing down even further? For having increased the dynamic advance, even .92 sounds a little on the higher end of things. From what I recall, Giles recommends around .85 for his pumps, though I have no idea just how much dynamic advance he puts in.
• #10 by RabbitJockey on 06 Oct, 2013 19:48
• I agree maybe try back it off more.  Large plunger will also inject more fuel sooner
• #11 by 8v-of-fury on 07 Oct, 2013 17:34
• Truth, but usually with a larger plunger you need more static advance.
• #12 by RabbitJockey on 10 Oct, 2013 05:40
• Quote from: 8v-of-fury on 07 Oct, 2013 17:34

  Truth, but usually with a larger plunger you need more static advance.
  

  
  thats interesting
• #13 by carrizog60 on 10 Oct, 2013 14:32
• wouldnt that make noise be too loud?
• #14 by Blocksmith on 10 Oct, 2013 15:32
• Quote from: 8v-of-fury on 07 Oct, 2013 17:34

  Truth, but usually with a larger plunger you need more static advance.
  

  
  Really?    That's rather counter intuitive; how does that work?