mk1 1.9TDI in progress

[mollins]

Hello diesel people.

For those that arent frequently browsing the mk1 forums you may not know im trying to build a TDI mk1.

I'll be keeping the tech chat in this new thread in the diesel section to keep the forum more organised.

I'm using a 1.9 1Z which comes in late 90's mk3, passat, T4 etc in the rest of the world.

The engine was imported without an ECU etc. so Ill be ditching the electronically controlled pump and going with the so called "M-tdi" option which uses the older mechnically controlled Bosch VE pump with a TDI camplate and rotor which bring up the pressure to suit the TDI engine.

I bought an M-tdi ready pump straight from a pump-builder in the US which uses an AAZ (1.9td indirect injection) pump body. This should hopefullly get the 1Z running and then I cant play with governers and timing to get the car running how i want it.

this is the 1Z in all its glory this morning.. after a bit of a tidy up and pulling off all that pesky electronic wiring



then good bye to the evil electronic controlled injector pump



this is the 1Z electronic pump on the left, and my rebuilt AAZ (indirect injection 1.9) pump on the right. The AAZ pump has TDI camplate and rotor in it, which makes it able to run higher TDI pressures, but without needing an ECU to run the pump, making this a so-called "M-TDI"



fitting up the new pump



here is my cheapo chinese turbo. It's a copy of a k04 turbo. I dont think i'll be using it. Ive got some other options as i have a 4 stud manifold from my 1.6 td which means i can use a k14 or T3. The 1Z came out with the both the k03 or k14 originally.




Currently held up as I need a new injector pump pulley to fit the AAZ pump. Should be able to get one from the states pretty cheap.

[Preen59]

Love it man. Subscribed...

[mollins]

That was fast preen.
BTW. I fixed my alternator mount problem. I'll show you when it arrives. It will be posted up here

[GoLfMan]

awesome!!!! i like where this i going....

say NO to cheap chinese crap!!!!

[Preen59]

That was fast preen.
BTW. I fixed my alternator mount problem. I'll show you when it arrives. It will be posted up here

I've got my eye on the ball see...

Yeah i'll be interested to have a look. What did you end up going with?

[mollins]

What did you end up going with?

its in the post. patience. time will tell.

[cetane]

Compression ratios?

Looks good!

How does the M-Tdi pump cope with the reduced compression ratio of the 1.9 ECU controlled motor? Without looking it up, I think it's 19 or so :1 The revised cam plate will alter the volume and perhaps the timing/length of injection.

Also, the injectors are different. What mods are necessary?

There's probably plenty of scope to play around with boost pressure and other turbo tweaks. Are you going to intercool it?

Good to see one of the original VWWA members doing something radical. And even better, including we dieselers in the updates!

[Greg Roles]

Nice work, love to have the time to pull the donk out like you did on the MK5 and mess with it.

Hope you have some decent intercooling ideas to back up all the great work thus far, and allow you the ceiling for said boost pressure tweaking!

Look forward to seeing your progress young oiler

[mollins]

How does the M-Tdi pump cope with the reduced compression ratio of the 1.9 ECU controlled motor? Without looking it up, I think it's 19 or so :1
The revised cam plate will alter the volume and perhaps the timing/length of injection.
Also, the injectors are different. What mods are necessary?

correct, comp ratio is lower at 19.5:1
the pump doesnt have any feedback from the engine, just sets a pressure curve for each injector line. I am using TDI injectors and therefore the breaking pressure will be the same as if it was using a 1z pump. The timing will be the hard bit. I think the direct injection will require me to time the pump differently, but i'll deal with that when I come to it

There's probably plenty of scope to play around with boost pressure and other turbo tweaks. Are you going to intercool it?

yes will be intercooled. will be running 10-20psi to start with

[Jarred]

yes will be intercooled. will be running 10-20psi to start with

thats a pretty big range "to start with"

bugger it. go straight for 20psi! hahahaha no don't, gah, im sure you'll figure it out

[GoLfMan]

goddam it i wanna see 30psi

[gldgti]

the differences between the 1z and aaz (in my mk3) aren't so great, especially in the bottom end, with crank, rods, block all identical. the boost pressure that mike will be able to run is safe enough at 20 (its fine on my aaz), even without an intercooler (though not optimal).

i suspect we may be "dynamically" timing the enine once its running in order to get it going well.

theres lots of fun to come.

[Preen59]

theres lots of fun to come.

I'm on the edge of my seat..

[Volvo Driver]

stick a big intercooler on it and a bigger turbo then that, they are fairly restricted stock.

Your living my dream of a TDi in a Mk1, but I would prefer the electronic pump myself, way easier to work on in general IMO. (based on the bigger stuff I work on)

[mollins]

stick a big intercooler on it and a bigger turbo then that, they are fairly restricted stock.

i have front mount cooler, much better than the stoopid mk3 side setup ... and the turbo will be a K04 which is a fair whack bigger than the standard k03 or k14.

Your living my dream of a TDi in a Mk1, but I would prefer the electronic pump myself, way easier to work on in general IMO. (based on the bigger stuff I work on)

you can have your electronic pump. makes sense with a stock setup car. i had no loom and no ecu. so mechanical it is. plus i like things i can see and adjust and tamper with, none of this chip flashing or laptop-in-car-crap. The Bosch VE pump is an absolutely amazing piece of engineering. The more i play with them the more it blows my mind.

this way, i can remap my fuel and advance curve any day for free!!