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TDIConversionsDiscussionsonconvertingnonTDIsintoTDIS.Moregeneralitemscanbeansweredbetterinothersections.Thisisidealforissuesthatdon't
haveanoverlapandareveryspecialtoswapingengines.

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February11th,2006,14:45

xriss
Newbie

JoinDate:Feb2006
Location:SCOTLAND

#1
mechanicalpump

hicananybodyhelpme...regardingamechanicalpumpforaVWGOLF1.9tdi90hpmodel....imtransplantinginto
avwsyncrocaravelandiwanttogetridofthewiring...sensorsect...hasanybodydonethis?iemappedormade
apumpforthislump??pleaseadviseonwhereicangetmyhandsonone...cheersallscottishchris

February11th,2006,18:48
http://forums.tdiclub.com/showthread.php?t=130079

#2
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RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:SouthernTier,
CentralNewYork
TDI(s):1981RabbitGTD
(futureTDI)

youhaveaPM...Icanpointyouinthedirectionof"what"todo...
Joe

February11th,2006,19:02

#3

michigandon
VeteranMember

Joe,couldIpossiblytroubleyouforthatinformationaswell?
Wouldlovetoknowhowtoconvertoneofthesethingstoallmechanical!

JoinDate:Feb2006
Location:WakeForest,NC
TDI(s):1998A3
FuelEconomy:44best,38
worst

Thanks,
Don

February11th,2006,19:15

#4

gidb36
VeteranMember

JoinDate:Jan2005
Location:SiouxFalls,SD
TDI(s):
Beetle,1998,White,1988
SuzukiSamuraiwithEcodiesel
installed
FuelEconomy:54/39/29

Metoo?SorrytobeapestbutIwouldlovetoputoneoftheseinasuzukisamuraiwithourthewiring.
Thanks,Gid

February11th,2006,19:29

#5

Thumbsmasher
http://forums.tdiclub.com/showthread.php?t=130079

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Canthisinfobeputuponthispost?Otherwise,I'llhavetobotherJoeaswell.

Newbie

JoinDate:Dec2003

Thanks

February12th,2006,
07:43

#6

RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:Southern
Tier,CentralNewYork
TDI(s):1981Rabbit
GTD(futureTDI)

ThisisbasicallyacopyofthePMisenttoxriss.TheonlythinkIhopehereisthatoutofthistheinfoultimatelyisbeing
usedforpersonaluse...notforthosetomakemoneyoffitbydoingitforothers.Ihaveshareditwithotherswhohave
donejustthatandIwouldhavebeenalloveritexceptforthefactthatIjustdon'thavethatmuch"extra"moneyto
buyextrapumps,etc.todothis...Anyways...
TherearethehybridpumpsthatpeopleusewhichbasicallyistakinganolderturbodieselpumpfromsayanolderVW
IDITDandusingitsmechanicalgutsandthenswappinginthecamplateand10mmheadfromtheelectronicTDIpump
intoit.Itworks...isn'tthebestwayforafewreasons.Thebasepartofthepumpusedforthehybridwasmadeinitally
toworkontheolder,muchlowerinjectionpressureIDIengines.Thereforewhenturningthepressuresneededtopower
theTDIengineneedstheshaftscansnap,aswellasotherthingsgowrong.Generally,allthehybridsIhaveseendon't
putoutthepowerpotentialtheypossiblycould...oriftheydo...theydon'tdoitsafelyIMO.Therearethosethatswap
thestraightIDIVWpumpontotheTDIaswell...butonceagain...asmentioned,theIDImotorsoperateatabouthalfthe
injectionpressurethattheTDIdoes...so,withthepumpfullyturnedup...you'donlybegettingtostockTDIhp/tqfigures
ormaybeslightlyover.
ThenthereisthemethodthatIhavegoneaboutdoingandwetriedandtestedmypumpinitiallyonmyfriendsSynchro
VanagonWestfaliamTDIsetup.I'msureyouallhaveseenorheardofKarlMullendore.Hewasrunningahybridpump.
IthoughtofusingtheCummins4btinjectionpumpwhichisthesamestylepumpasusedontheolderIDIVW'saswell
astheTDI's,butthisisaDI(directinjection)specificfuelinjectionpump.Thecumminsengineitwasmadeforis
similartotheVWTDIandoperatesinandaroundthesameinjectionpressures.Thepumphasalargermainshaftas
comparedtothatoftheIDIstyleVEpumpssoitcaneasilyturntheinjectionpressuresneededfortheTDI.Theyare
alsofairlyeasytofindtooandtheswapisn'tallthathard.Thesmoothnessatwhichtheyrunthemotorisamazingand
thepowertovouch.Theonlymajormodificationsrequiredisthatyoumustswapthegov.componentsofaVWTD
mechanicalpumpintothecumminsgov.housing,oruseanentireVWgov.assemblyinthecumminspump.The
cumminspumpinstockformhasatotallydifferentstylegov(asthiscameofdeliveryvanstyleapplicationsthatrev.
verylow)comparedtowhatisneededtosupplyfuelfrom04800+rpms...thedetailswouldbeforanotherpost,ona
moreindividualbasis...
Letmeknowifyouwantmoreinfo,etc.orneedhelp...IcanprovidewhateverIcanovertheinternethereandsuch.
Thisisn'talltheinfojustfortheabovepurposes.IalsoknowthatKarlaftertestingminewasabletobuyafewextras
aswellandmightbewillingtodothemforpeoplebutthereareafewpartsthatare"harder"tofindandthusmakeit
difficulttojustdoonaregularbasis...
Hereisalsoasitethatsells"mechanical"TDIpumpsaswell,Karlpointedthisouttome...intheUKIbelieve,seems

http://forums.tdiclub.com/showthread.php?t=130079

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likeanhonestguyandthepumpheisusinglookssimilartomy4btpumpandKarls.
http://www.syncroberndjaeger.de/EN...neuer_tdi.html
Alittlepricey...canbedef.doneforcheaperthanthat...but,itsanoption...justthoughtI'dthrowthelinkoutthereto
you...
Thereareotherissuessuchastheinjectionpumpsprockettodealwithusingthe4btcumminspump(cumminsnoseis
shorterthanthatoftheTDIpumpnose),butitsafairlysimplefixandsuch...andthedriveabilityandpowerofitis
amazing.InmycaseImachinedthebeefyMKIVstyleinjectionpumppulleyandturneditbackwardsonthehub...lines
rightup.ForKarl'spurposesheuseda1.9AAZpumppulley(whichisadjustableaswell)andturneditbackwardsonthe
hub.Itsalittlelessbeefyinconstruction...butworks.ItsalsostillavailablethroughthedealerorWorldImpex...around
the$50.00pricetagarea.Wouldstillneedtofindthe"hub"theadjustableunitssetonthoughtoo.Theotheroptionisto
machinetheold1.6stylepulleyatthemachineshoptofitproperlyontheCumminspumpnose.Alotofoptions...I
personallylikedtheideaoftheadjustableunitmyself.Iforsee"preset"advancemarksforsaymakingarunonthe
trackvs.normalhighwaydriving,etc.justtoeasilyset,adjustandcheckagainstthegaugebylooseningthreeboltsin
onelocationvs.4ontheoldstyleandMK3/B4stylesetups...
Hereareafewpics.
TheMKIVstyleTDIpumpvs.theCummins4btpump(beforemodificationofthegov.assembly)notethedifferences
betweenthe"noses"ofthepumps...

http://forums.tdiclub.com/showthread.php?t=130079

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Also,theMKIVstyleinjectionpumpsprocketpriortomachining

http://forums.tdiclub.com/showthread.php?t=130079

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Partialsofthedifferencebetweenthecumminsgov.assembly(RIGHT)andtheVWTDstyleassembly(LEFT).

http://forums.tdiclub.com/showthread.php?t=130079

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MKIVstyleinjectionpumpsprocketaftermachining...had"bubble"removedfromthefrontsideofthesprocketsoit
couldbeturnedbackwardsonthehubandlineupthecamshaft,etc.relativetothepumpwithouthittingtheinjection
pumpbracket...

http://forums.tdiclub.com/showthread.php?t=130079

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mechanicalpumpTDIClubForums

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4btpumpwithVWTDthrottleshaftbushingtransferredto4btpumpaswellasVWTDthrottleshaftandcagedgov.
assembly.StillmoretobedoneandmoreKarlandIaretalkingabout...thisdoesn'tdetaileverything...butyougetthe
idea.

http://forums.tdiclub.com/showthread.php?t=130079

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maybeKarlwillseethisandchimeinonhowhefeelsaboutitinhisvan.Icantellyouthough,whenIhearditrun...
WOW sosmoothcomparedtoalltheothermechanicalTDI'si'veheard/seenandhesaidthepowerisjustas
impressive.
Joe
LasteditedbyRabbitGTDJoeFebruary12th,2006at07:55.

February12th,2006,08:28

#7

michigandon
VeteranMember

http://forums.tdiclub.com/showthread.php?t=130079

Wow!Almosttoomuchinformationtocomprehend...butit'sallgood!
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Willdefinitelybebookmarkingthisforfuturereference.

JoinDate:Feb2006
Location:WakeForest,NC
TDI(s):1998A3
FuelEconomy:44best,38
worst

February15th,2006,23:17

#8

michigandon
VeteranMember

Ifoundafewmoresourcesformechanicalpumpconversions:
http://www.syncroberndjaeger.de/EN...neuer_tdi.html

JoinDate:Feb2006
Location:WakeForest,NC
TDI(s):1998A3
FuelEconomy:44best,38
worst

http://vwdieselparts.com/jettatdift.htm
(scrolldowntowhereitsays"TheOptionToInstallATDIMotorInYourOlderA1orA2ChassisIsNowA
Reality").

February16th,2006,03:42

#9

RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:SouthernTier,
CentralNewYork
TDI(s):1981RabbitGTD
(futureTDI)

http://forums.tdiclub.com/showthread.php?t=130079

thatonelinkisthesamelinkthatisintheabovethread.Sameguy,samesite...sameprice...
TheotheristhroughJack...I'mwonderingwhat"route"theyaregoingabouttomakethemechanicalpumps?
MightbeworthaninquirybutI'msureitsthe"hybrid"route.Usinga1.6TDpumpbaseandswappingintheTDI
camplateandplunger/10mmheadassembly.Notrocketscienceagain...butnotthebestsolutionIMOeitherifthat
iswhattheyaredoing.Notabadpricethough,butacumminspumpcouldbesetupforaboutthesameoralittle
lessifyouhaveTDcoresaroundandwouldbeaDIspecificpumpmadetohandleDIinjectionpressuresandwill
outputthemaswell.
Nottoknockthosethathavethehybridpumpbecausemanyareupandrunningfine,justhaven'tseenmuchin
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thewayof"power"fromthem.Theenginewillrunthough

Joe
LasteditedbyRabbitGTDJoeFebruary16th,2006at03:47.

February16th,2006,08:22

#10

mojogoes
VeteranMember

JoinDate:May2003
Location:england
TDI(s):mk3tdigolf
FuelEconomy:notmuch

IthinkthisiswhatSimondidwithhismechanicalpumptoobutuseda11mmpandcamplate/12mm
plunger......hesaiditflowedmorethantwicethatofa10/11mmandr520's.
__________________
A3/mk3golfwith249Whp"Nowinthehandsofsomeoneelse"

February16th,2006,09:06

#11

RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:SouthernTier,
CentralNewYork
TDI(s):1981RabbitGTD
(futureTDI)

It'dbeinterestingtohearwhathedid...especiallywiththepowerhewasputtingdownwiththatintialsetup.I'd
beinterestedinwhetheritwasaIDIpumpbasew/thesmallerinputshaftorwhetheritwasaDIspecificpump,
orapumpedbasedonalargerinputshafttobeginwith.ForsomereasonithinkIrememberemailingwithhim
andhimsayingthatitwasNOTanVWIDIpumpbase.
Joe

February22nd,2006,17:59

#12

piper106
Member

JoinDate:Apr2002
Location:GrosseIleMI
TDI(s):2001NewBeetleBlue
FuelEconomy:44/40/37

Therehasbeenalotofdiscussiononthissubjectoveratvwdiesel.net
AsfarasIknowtheearlierVW1.6LNAandTurboinjectionpumpsuseda17mmdriveshaft,anda9.5mm
plunger.BoschpumpsontheVWTDI,andtheCummins4BTbothhad20mmdriveshafts,theTDIpumphaving
eithera10mmplunger(manualtranscars)or11mm(autotrans),bothbeingelectroniccontrol,theCummins
4BThavinga12mmplungerandmechanicalcontrol.Therearealsodifferencesinthecamplate(theTDI
camplatehasthemostliftandtheriseisquickerthantheotherpumps)andthedeliveryvalves.
Nowcomestheinterestingpart.Havebeentoldthatatleastsomeofthe92to98VWIDIturbodieselssoldin

http://forums.tdiclub.com/showthread.php?t=130079

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Canadawithfullymechanicalpumpshavea20mmdriveshaft.SwapintheTDIplunger,camplate,anddelivery
valves,youaregoodtogo.
ThatisallIthinkIknow.
Piper106

February23rd,2006,02:45

#13

RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:SouthernTier,
CentralNewYork
TDI(s):1981RabbitGTD
(futureTDI)

Youarecorrect....someAAZ1.9IDIinjectionpumpsdohavethelargerinputshaftlikethe4btpumpandmake
excellentdonorswhentheTDIcamplateand10,11mmheadareadded.Thecamplateisveryspecificbetween
IDIandDIengines.Ifyoulookatacummins4btcamplateithasasimilarcurvetotheTDI10mmunitbuthas
about20%moreliftonthetopofit...
It'dbenicetocompareaTDI11mmcamplatetothat...
AAZpumpsarehardertofind...thuswhyidon'tthinkyouseemorepeopleusingthem...
Joe

February25th,2006,04:27

#14

mojogoes
VeteranMember

JoinDate:May2003
Location:england
TDI(s):mk3tdigolf
FuelEconomy:notmuch

Joedoyouthinkthe11mmcamplatewillbe/havethesamehigherliftasthecummins4btcamplate?
__________________
A3/mk3golfwith249Whp"Nowinthehandsofsomeoneelse"

February25th,2006,07:43

#15

RabbitGTDJoe
VeteranMember

JoinDate:Aug2005
Location:SouthernTier,
CentralNewYork
TDI(s):1981RabbitGTD
(futureTDI)

http://forums.tdiclub.com/showthread.php?t=130079

I'mgoingtoguessthatthe11mmcamplateisgoingtohaveasimilarprofiletoitasthe12mmbutIdon'tthinkit
willhaveasmuchliftasthe12mmunit.I'dreallylovetogetmyhandsononetoseeandcompareittotheTDI
10mmandthe4bt's12mm.
Joe

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