Club 80-90 Forums

Anyone know of a cheap(er) alternative to the £1500 mechanical fuel (sold by a certain German Bulli specialist who has possibly the worst customer service I have ever come across, gave up virtually begging to buy a £400 fuel tank of him) pump for a TDI conversion? Am told that there is a Peugeot pump that will fit (on a 1z engine) Was also told Andy Simpson was the Guru but am having difficulty getting hold of him. IN Cornwall so Syncronuts is a bit of a drive. Any thoughts anyone?

That sertain bully spesialist's pump is 2600euro plus you need the maching injectors atr 1000 euro.
There is no straight bolt on MTDI pump.There are a lot of pumps that will physicaly fit but whont run the engine.
Russel

Check out this guy here in Canada. He does amazing things with pumps for not much more than a regular pump rebuild- usually about $ 800 CND.
It's a bit far to ship but i garantee you will be happy with the results.
http://vwdiesel.net/phpBB/viewtopic.php?t=3100.
Check out this also
http://vwdiesel.net/phpBB/viewtopic.php?t=14734.
The german guy is fine but why pay 3 times the money for nothing.

Thanks cveman and Russ. Got to selll the splitty before I get cash to do anything.

Echo on Caveman's comments. Giles Gallie in Toronto is a very good guy to deal with, and has a humongous good reputation amongst the TD and m-TDI set here in NA. We have him doing a 2.5TDI to m-TDI for our T3 Syncro project now.

For the real diehards, there is enough information around the www.vwdiesel.net website to do the DIY conversion, if you so desire.

Loads of info out there if you only search for it.
Also loads of possibles for a pump, just get your local Diesel place to put it together for you.
Basically find a donor pump and fit the cam plate from the TDI pump, and use your Diesel mans judgement to set up the advance.
11mm head and rotor is a good idea.
injectors from a AFN (or other 110hp engines) is a healthy upgrade.
Must be inter cooled, or charge cooled.
Can be put together as a JX more or less, so super simple.

Well this all depends wether you want a tested and proven setup or a maybe it will work if i try hard enough.
The big thing on a mTDI is longliverty of which ive seen plenty of failures at.
I use proven pumps,costs more than a shot in the dark but hey they dont packup after 10 000miles.
There are a handfull of good supplyers out there that stand by their work and have been proven over more than the 100 000 mile range.
Russel

I think Russel is right.........you cant just start changing cam plates and stuff inside a stock AAZ pump for example, I know someone who thought he was doing the right thing by putting all the TDI pump guts into a Small shaft AAZ pump.......results.......it lasted for a few thousand miles....then broke.....
You either get a proper pump built........or stick with a stock AAZ pump, as I have and put up with the fact the engine only produces around the same power as a 1.6td......
We have now done over 25,000 trouble free miles with this set up, the bus is still happy to sit at 70mph all day long and will do 80, but thats 4,000rpm and not what I call cruising!!! It returns 40+mpg and we still get to overtake cars towing caravans up hills. Its what I would call a good all rounder with proven reliability....(1.9 AHU TDI on AAZ pump and VW Sharon intercooler)
Some tips, if you use AFN injectors, dont use a small shaft(17mm) pump, AFN injectors have more spring pressure to insure the larger nozzles can atomise the fuel correctly... So stick with large shaft (20mm?) pumps.
The less powerfull AHU engine is better suited to a stock AAZ pump, you still need to 'play' with the pump and set up the fuel metering and residual fuel to get them smooth, but once done, they run fine......Im living testiment to that......
GaV

HOT 1200 wrote:I think Russel is right.........you cant just start changing cam plates and stuff inside a stock AAZ pump for example, I know someone who thought he was doing the right thing by putting all the TDI pump guts into a Small shaft AAZ pump.......results.......it lasted for a few thousand miles....then broke.....
You either get a proper pump built........or stick with a stock AAZ pump, as I have and put up with the fact the engine only produces around the same power as a 1.6td......
We have now done over 25,000 trouble free miles with this set up, the bus is still happy to sit at 70mph all day long and will do 80, but thats 4,000rpm and not what I call cruising!!! It returns 40+mpg and we still get to overtake cars towing caravans up hills. Its what I would call a good all rounder with proven reliability....(1.9 AHU TDI on AAZ pump and VW Sharon intercooler)
Some tips, if you use AFN injectors, dont use a small shaft(17mm) pump, AFN injectors have more spring pressure to insure the larger nozzles can atomise the fuel correctly... So stick with large shaft (20mm?) pumps.
The less powerfull AHU engine is better suited to a stock AAZ pump, you still need to 'play' with the pump and set up the fuel metering and residual fuel to get them smooth, but once done, they run fine......Im living testiment to that......
GaV

AAZ pump is never going to run a tdi PROPERLY, head is too small, cam plate is totally wrong, will not advance enough, LDA pin is a waste of metal and all this is assuming you have one of the best of the four types of AAZ pump. VW must of really screwed bosch with the price of pumps for AAZ's because they are very basic/poor spec compared to other bosch equipped cars.

Putting together a proper mechanical pump is not rocket science, they can be made to easilly out perform the electronic tdi's and push the engine way past its limits as i have proven too many times this year.

Or alternatively you could go the Pumpe Deuse route!

syncrodoug wrote:Or alternatively you could go the Pumpe Deuse route!

I have done now

We'll have to compare notes when next we meet - you going to Vanfest?

syncrodoug wrote:We'll have to compare notes when next we meet - you going to Vanfest?

No not going to vanfest.

Mine could pass for being a factory fit.

So our mTDI pump has been on for nearly a year now. Has done well over 12k and has just completed a 2500mile trip to Pyrenees - never missed a beat.
Glow plugs aren't connected, starts first time.

In fact the competition was start it the same time as our galaxy (same engine) and it always starts before galaxy does.

Oh forgot Pyrenees trip returned an overall average of 28/29mpg (sure Clive will be along soon and correct me) fully laden (well over 2.5 tonne)

I seem to have set up my AZZ pump to give good all round performance....
Its quicker than a 1.6td
Gives 40mpg
Sits at 75mph nicely

All I did was give the pump 1.2mm adv timing
fit a GTD boost pin
Turn up the main fuel screw
Lock down the residual fuel screw
Fit an intercooler
FIt a straight out exhaust
26,000 miles later, its still running, and motored at 80mph with the scooby T25's to slough swap meet last year.........
I think as a daily driver, including school runs, shopping trips, commuting etc......its pefect........and had two great touring holidays clocking up over 3,000 miles between them........GaV

I didnt want full blown grunt that breaks stuff, I mearly needed to replace the leaky/broken 1.9 wbx engine.......and never go near petrol again