An old LDA...

...looks like this.

(Upon request from a forum)

Q: Is it possible to run a TDI with an AAZ pump?

A: YES!

Here's som info about the topic. I've taken this info from vwdiesel.net that was taken from brick-yard.co.uk. This is high valued information so I think it's worth saving here too!


Hi Folks, not been on here for a while...

Just thought I would drop you an update, Now clocked up just over 55,000 miles since the mTDI conversion on my 87 Caravelle. Mechanical failures in that time include Starter Motor & water pump.....thats it!

Actualy thats not true, the Gearbox  gave way last week with a locked up diff..........Accelerating up a gentle hill and 'BANG', kicked out of gear and one back wheel locked......Ooops!

So, now on the hunt for another gearbox.

Anyone considering this budget conversion, (AHU 1.9 TDI, AZZ pump, GTD Boost Pin, Sharan Intercooler) go for it, it's been a joy to drive for the last 4 years. Has always given me 400+ miles on a tank of fuel.

(the box clocked up 205,000 miles before it let go.......so not too bad!)

...

The internal's of the pump are not modified, however the fuel metering is.....its very easy, you shut down the idle screw on the trottle arm so the throttle arm is fully closed. This means you lose tick over speed, however you then adust the main fuel delivery screw on the back of the pump and set your idle with this instead. (you must also shut down/back off the residual fuel screw that compensate for Air Con. Dont worry, you will never overfuel it, even when using the boost pin to its most aggressive position, smoke is hardly visiable. But you must make sure the main delivery scew is worked with in 1/8 increments, it is very sensive, turn it too far out and you could risk diesel runaway. The golden rule is to make sure the engine returns to idle within 3 seconds of revving up high. I made my own boost pin for even more power and only then was I getting some black smoke, driving with the home made boost pin was amazing and I could Pull from 30mph to over 80mph in 5th!!! I lost MPG so reverted back to the adustable GTD boost pin( can pull 35mph to 80 in 5th, so only lost a tiny bit) I posted a massive page on here years ago in great detail how to do it (I have worked with Marine diesel engines most of my life, so I knew what I was doing.
You must then give the pump a touch more advance (timing) because the AAZ pump takes a lilttle longer to build up the required working pressure to lift the injecter needles.....
Providing you are not getting black smoke and you havent messed aroudn with the Turbo waste gate, you wont need to worry about exessive ehaust manifold temps either, its all very simple.
If anyting the TDI's run cooler than the AAZ engines because the greatly increased head efficiency and direct injection properties. Indirect (AAZ) engines, the combustion starts in the Howard chambers which greatly increases head temps. TDI's run much cooler, I have sat for hours in the nasty cornwall summer traffic jams, I have never once had the cooling fans kick in and Im still runnning the smaller petrol radiator!!!
I used to have a good 1.6TD crew cab, its every bit as powerful with more torque and stonks along the motorway (I held it at 70mph for over 7 hrs driving back from cornwall through the night, no problems. Flat out it does a smidge over 80mph, (94mph down hill is the most I have ever had) but this is the limitations of gearing and pure BHP.
Shame the box broke, it was a rare one, (8D) nice and high geared similer to the more desirable AAP BOX.
As for budget conversion, Home made left hand engine mount, exhaust and intercooler plumbing. Engine out of a 98 MK3 Golf Estate, AAZ pump of the shelf from the scrap yard and the intercooler.
Stock T3D flywheel and clutch, gearbox was £50 of ebay......so had my monies work out of the box LOL.......Never thought I would get 55,000 trouble free miles........amazing!
 
As for comparison to newer stuff, I drive a 57 plate 1.7Common Rail Astra van for my work everyday, the Velle feels more responsive with no Turbo lag and more torque. The Astra feels half asleep. I must be getting pretty good power becaue I can fly past all those bay window's climbing hills in Cornwall........LOL


The entire thread can be found here: http://www.brick-yard.co.uk/forum/mtdi-55000-mile-update_topic62248.html

New bus and all of a sudden new plans

Now back after a long trip and two things were on the agenda, converting the Caravelle with an AAZ and TDI'ing the old pickup.
I was talking to a friend who scraps nothing but T25's to gather the parts for the AAZ project when all of a sudden he says "but hey. I have a working Multivan WITH diesel. Why don't take that one instead and give me the Caravelle with the broken engine?". So instead of buying the parts I get a working Multivan for just a little bit more money! :)

We now decided to change plans. The TDI and the AAP gearbox goes into the Multivan and the turbodiesel from the Multivan goes into the pickup! Super easy upgrade on both and no rebuilding for gearboxes or engines needed. They just fit as is! :)

How to replace seals in a VP37

Here's a detailed description for replacing the seals in a VE-pump. I was thinking it might be a good idea to post it rather than forgetting it...

http://cid-f04c9febf9c651ec.office.live.com/view.aspx/Bilder%20f%C3%B6r%20webbwn/Packningsbyte%20och%20justering%20l%C3%A4gesgivare.doc

The workshop is very nice now, I think I'll post pictures later. :)

Let's make a workshop!

Really need to get the new workshop in business, so I started with the roller shelves tonight. I'll make four of them and the volume of storage is massive, as a bonus there will be 1,5 meter left to the ceiling as an extra storage area.

Doing the moving, slow progress

At the moment I have made a temporarly storage in the new workshop, I still have a few things to move from the old place. There's just a small problem, the "few items" weigh a couple of hundred kilo's. Each...

Garage idea

I will have an expandable room for sanding, when I do big things I just - that's right - expand it.

The shelfs are running on wheels in a track. I have the same setup in the old garage and I can really store stuff in them, the storage volume becomes massive.

Another layer on the floor

Uge difference!

The paint kit says that I had less paint than needed, but if I should have been going with the recommendation I've could have painted the walls as well. The last layer was thick, and I mean really thick. 

Finally! New garage

Yehaa!

Started with floor painting yesterday. Really cold outside but the entire floor has integrated heating so I believe it will harden anyway.

MOT means rust fixing

I crawled under the pickup just to check a measurement and thought that the left side inner sill looked a little bit tired. I took a big screw driver and knocked it with the tip and *crack* straight through! Hmm... I hate rust. Need to do the MOT so I decided to fix it the easy way, and never-get-a-problem-with-sills-again way, that means I replaced the sill by double welded 2 mm 50x50 square tubes and 1 mm galvanized sheet.

Of course, when you start cutting there will be more. I ended up replacing pieces of the floor, a part of the torpedo wall, the outer sills, a piece of the wheel house and the vertical beam in front of the rear wheel. I actually ended up booking a new date for the MOT. I have to do an ugly fix for the hatch as well, I had to cut it open as the lock was totally rusted. I'm going to do some glass/carbon fibre parts for the pickup and new hatches are first in the list, so I'm not going to put any energy on these ugly bastards.

I also found out that the bed floor is damaged and that's probably why it has an extra layer of metal sheet on top. Some of the bed outriggers needs to be replaced as well. So the new plan is as following:

As soon we are in the new workshop, I'll cut the bed of totally.

Remove the engine and gearbox.

Replace everything that needs to be fixed, I'll get the material from a company nearby.

Rust protect everything and repaint.

New engine/gearbox in.

Totally new bed floor made out of galvanized sheets.

Burn out!

Oooh, I can't wait to have my workshop at home!!!