Need help with IP models! Updated with pics! - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Need help with IP models! Updated with pics! by Sierra94 on 13 Nov, 2006 08:31
• First of all I wanna say hi! I´m new on the board. I´ve just been working on bigger Chevy diesels before but decided to get a VW Caddy -99 as a daily driver.
  
  My problem is this: I fitted a turbo from a Golf -93 on my Caddy and that works great. But now I need another Injection pump.
  
  Which model should I look for? I bought a pump from a -86 1.6 TD but the axle with the pulley seems to short.
  
  So I decided to ask here instead of trying and testfitting other different pumps with no luck.
  
  Sorry for the long post and all. Thanks in advance!
• #1 by Sierra94 on 13 Nov, 2006 15:42
• I took some pictures of the "new" pump I bought and the one I have in the car right now (bad angle).
  
  My question still is if I can take the pulley I have on my old pump even though it´s without a key and put it on the "new" pump with key and have everything lined up properly. The input axle seems shorter on the "new" one comparing to the one on the engine. Just a visual compare.
  
  If that work I just have to solve the cold start vaacum actuator and maybe getting some other fuel lines.
  
  The Nr of the "new" one: 0460 494152
  
  Is the pressure actuator some kind of LDA? It controls a pin inside which is excentric.
  
  
  
  
  
  
  
  
  
  Thanks again!
• #2 by LeeG on 13 Nov, 2006 22:53
• your '86 pump looks like it came off a TD vanagon, and yes, that pressure actuator is for the LDA.  They used that setup on vanagons to keep the profile lower, same with that throttle arm bent down the side of pump.
  
  Can't help you with the pulley question, but will be watching to learn the answer!
  
  Whats a '99 caddy have in it, a 1.9 NA?  We never got them this side of the pond.
• #3 by Sierra94 on 14 Nov, 2006 04:21
• Yes, it´s a 1.9 NA. 64 bhp.
  This is what it looks like now.
  
  
• #4 by Slave2School on 14 Nov, 2006 05:26
• Do you like trucks?    Quite the collection!
• #5 by ISBjornen on 14 Nov, 2006 06:11
• hello and welcome to the board.
  
  You nead to ask your self. how mutch power do you want and waths the maximum cost.
  
  I could get you 150hp if you like.
  
  If you want to know more, just ask. och call 0730-698084 or msn [email protected]
  
  //Mattias
  Sweden, Malmoe
• #6 by Baxter on 14 Nov, 2006 10:35
• Yep, Deffo a JX pump.
  I just had one in pieces trying to see if there is anyway of adjusting the LDA to cope with anymore than .5 bar of boost, looks like a lot of messing TBH.
• #7 by Sierra94 on 14 Nov, 2006 13:14
• I found a TD pump from a VW Passat -92 at the local junkyard today but it had the "fake" lda on top. (would that be a AAZ?) There was nothing under the lid on top. So I took the pump lid from the old vanagon pump and put that on the Passat pump along with the pressure actuator etc. I got hold of the belt pulley and fuel lines aswell, so it wouldn´t be a problem getting it to fit now I hope. Also did the governor mod while at it
  
  So hopefully I will have a working pump on by tomorrow.
  
  Yeah, I love trucks! A more useful set of wheels is hard to find. And as long as it has the same performance as a regular car I don´t mind.
  
  The big Chevy truck in my sigpic has a 6.5 TD V8 engine and a 5 speed manual tranny.
• #8 by Baxter on 15 Nov, 2006 11:18
• I had a van in the garage that was blathered in Oettinger stickers. I thought nothing of it until I opened the lid and there was a charge cooler, after a bit of digging I found out that the conversion was actually a Oettinger 90hp kit.
  Anyway, I have seen what Oettinger did to the LDA and it wasn't pretty!
  From what I could see they had (Whoever fitted the kit, or messed with it in the past) cut off the stop to get more travel on the lever before it drops into the pump.
  The LDA shaft had bits welded onto it.
  
  I was quite curious as to what pressure the LDA topped out so I rigged an airline, pressure regulator and a gauge up to it to see what happened, as pressure increased so did the LDA movement till it got to .5 bar, this was about 3/4's travel, then anything over .5 bar the LDA just went right to the end of the travel! Operation above .5 bar was a bit jerky to say the least. I drove the van and I have to say it didn't feel particularly quick, just felt normal, and the boost pressure was just standard so I think someone had backed the turbo off at some point.
  
  I think the only way to get a JX LDA to offer more fuel over .5 bar would be to.
   
  * Add a spring to the LDA to get it to work over a greater pressure range.
  * Grind the stop off so the shaft can turn further.
  * Grind the ball joint from the push rod to the lever and move it in slightly.
  
  I have a spare pump under the bench I have been playing with and wondering how to improve it to offer a better alternative to notching the engine lid.
  If I remember I will take some pictures and see if anyone else has any ideas on how to make it better, It's just another one of those jobs I will get 'round to eventually! Priority is getting customers vans done, I can mess with my own stuff in my own time!
• #9 by Sierra94 on 16 Nov, 2006 11:51
• Hehe! That´s all I can say at the moment!
  
  Just got my new IP to work properly in the Caddy. I took the 2 pcs pulley from the original pump and machined it in a lathe to make it thinner and thereby get it to work with the shorter axle on the older pump. Big difference in adjusting the timing. I have´t used a dial indicator yet but I will try and get hold of one a.s.a.p. But it starts easy and runs really great anyway. But it´s surely not exaclty timed right now.
  
  I turned the fuel up and set the boost pressure to 1 bar and what a little devil the 1.9 it became instantly.
  
  Corrected the LDA pressure actuator with a heavier spring mounted on the push rod so it opens fully at approx 1 bar pressure. It now follows the whole power band from idle and up. Worked really great.
  
  I don´t know how much HP I gained by this but it feels a lot quicker than my girlfriends gasoline Golf3 1.6 anyway
  
  I will keep things updated as there´s a lot of work in progress. I´m gonna do some fine tuning with the pump timing and so on.
  
  Later!
• #10 by Baxter on 16 Nov, 2006 11:54
• If you strip the pump top off, you will see a shaft with a cam on it, I suppose this could be ground to a sharper angle as you do with the AAZ boost pins.
• #11 by Sierra94 on 16 Nov, 2006 12:05
• Yes, I have seen that one. I will try and get out and machine it to make the angles steeper. It could use more fuel but turning the fuel screw in more makes the idle very tricky to set. It wont come down in rpm for a long time after a rev. So I guess the pin with steeper angles would make it get more fuel in higher boost as the pin turns.
  
  Do you have any pin you have modified Mr brick? To fit that kind of LDA?
  Because the pin isn´t the same on the JX pump as on the regular LDA (saucer type) right?
  
  Thanks for all the help so far Some things have become really clear with the info this forum provided. I´m a typical trial and error kinda guy otherwise, but some things I do need help with.
• #12 by RabbitJockey on 16 Nov, 2006 14:26
• wtf pump is on his caddy now? looks almos tlike a tdi pump, but it has a throttle lever to it so i know it isn't, or is it?
• #13 by Baxter on 17 Nov, 2006 13:47
• Judging by the picture it looks like a Lucas pump, so I reckon the engine code is AEF.
• #14 by Baxter on 17 Nov, 2006 13:58
• Quote from: Sierra94

  Yes, I have seen that one. I will try and get out and machine it to make the angles steeper. It could use more fuel but turning the fuel screw in more makes the idle very tricky to set. It wont come down in rpm for a long time after a rev. So I guess the pin with steeper angles would make it get more fuel in higher boost as the pin turns.
  
  Do you have any pin you have modified Mr brick? To fit that kind of LDA?
  Because the pin isn´t the same on the JX pump as on the regular LDA (saucer type) right?
  
  Thanks for all the help so far Some things have become really clear with the info this forum provided. I´m a typical trial and error kinda guy otherwise, but some things I do need help with.

  
  
  I repair T3's all day, every day, I run one as my own vehicle and I still manage to be fairly enthusiastic about them, but, when I finish work I generally have better thing to do, like keeping them on the road.
  The notes I made above are from observatiuons I have made of the pump as I suppose I am in contact with them probably more than anyone else on this forum, but I have not got 'round to carrying out any of my ideas, it's nice to know someone else is playing with one and I for one will be very interested in your progress as, well, it saves me the hassle!
   :lol:
  I suppose adding a spring is similar to the star wheel adjustment, adding more spring tension makes the aneroid work over a greater pressure range, but then a cam with a steeper angle would give more fuel over a greater range of boost.
  I would suggest that you try to remove the stop that the LDA lever "Stops" against, and undo the push rod and set it so max movememnt on the LDA is when the lever gets to its stop.
  Also, the Oettinger one I saw had the pressure vessel removed and spaced away with washers, again I suppose to get it to work over a greater pressure range.
  For once, tomorrow I have a saturday when I am not playing catch up with a yard full of broken T3's, so I may get time to play but I have thought I would use the time to strip out a TDI crank and offer it up to my AAZ, plus I have valve guides and some match porting of the AAZ head to do.
   :shock: