1.5TD Pumps do exist (The 1.5TD project)

[saurkraut]

Here's my 1.5TD pump.

I used a Yellow dot 1.5 pump, and the LDA off a 1.6 pump.  Put them togather and sent them off to the local Bosch rebuilder.

One phone call to Germany by the rebuilder to find out what the heck is going on, and back it comes



They said that the Krauts in Germany said its a 1.5 TD pump, set up like a normal 1.5TD pump

They felt it necessary to retag the pump:



Its on now with the cam set, but not the pump.

Need to set the valve clearence, time the pump, recalibrat the break pressure on my injectors, finish the 2.5" exhaust, put the dash board back togather, connect a few nitnoid things, and the 1.5 TD winter beast will be on the road!

[blkboostedtruck]

you got a poptester up there? if not i got one down here! if you need to use it?
thanks Duane

[saurkraut]

Thanks for the offer, but I have access to a pop tester where the car currently resides: European Car Service in Ironwood Michigan.  Its a reasonable drive from here.

The only real hazard is the elk herd the DNR transplanted in the northern part of the state.  I don't know where they got these things.  They're freak'n huge!  Bigger than a horse, and about as smart.

The proprietor lets me work inside in the winter, and lets me use all the special tools.  Here is a view of the winter rabbit in work.  Its sitting below a TDi Beetle.





The details are: 2.5" exhast from the turbo to rear bumper, new bearings on all four corners, new breaks on all four corners, FN five speed, new CV joints, 14" jetta wheels, new radiator, reringed, new bearings, 1.6 flywheel and clutch, big oil pump, and Raceware 11mm head studs in the motor, rebuilt k24 turbo and 1.5TD franken pump.



I think I'm the only one who uses the pop tester, as the IDI drivers are becomeing few and far between.  I always have to collect a bunch of junk injectors, pull the shims, measure and sort them them, and then start calibrating.

Same thing with the machanical heads.  Last weekend, I was trying to use his valve shim kit, but its missing all the shims in the middle of the range.  I'll have to use my kit, and pull some heads apart to replenish the stock.

[blkboostedtruck]

ELK??? WOW you know DNR just gave you alternative transportation! a couple turn signals on the antlers and a running light on the butt and your good to go! L.O.L. :lol:  i'm suprised those canadians have not thought of that? or have they? :roll:  sorry! ahh i coud not resist! saukraut can you speak and understand german? or whats on that dieselsend website?
send me a P.M. and i'll give you my phone # or give me yours?
see if we can get something rolling here?
thanks Duane

[Baselyne]

what all did you add from the 1.6L td pump  to the 1.5L pump to make it a turbo pump before sending it into the local re-builder>?

[coke]

The LDA went from the 1.6TD pump to the 1.5L, its used to pump more fuel into the engine under boost.

[Baselyne]

is there a link to this sorta thing or? something around to give a newbe a clue whats involved in removing his LDA sos not F**K things up for both pumps.....>??

What's the number on the tag that the shop "re-tagged" when you took it in?

I'd like to know as much about this as possible because Im in the middle of clashing these two pumps togethor to get a 1.5Ltd pump

Laslty I must add in again that I think this is so cool what you've done here! Props to "Saurkraut"

[Ziptar]

So what is the Bosch number for a 1.5 TD pump? I can't see it in the photo.

[saurkraut]

I'll have to check, I don't remember.

[Baselyne]

I wish there was more clear info on a 1.5L TD

[saurkraut]

I wish there was more clear info on a 1.5L TD

Yes, me too

[saurkraut]

Well, I have a few miles on the 1.5TD project now.

I set the injectors to 170 bar, filled the banjo bolt on the compressore waste gate line with rtv, and unscrewed the other end of the line at the waste gate.

I have the LDA pin about 3/4 way to full ramp with the platic washer still in, full load screw set to 1/4 turn in.

It barely cracks 900F at full throttle, just a hint of smoke.  Booste is peaking at 15 PSI

Acceleration is good and it will accelerate in fifth gear above 65MPH.  Below that, forget it.  It will cruze below 65 in fifth, but acceleration is out of the question.

I think I'll back out the governor screw a healty amount and test that befor I add more fuel.

I have the Aircraft spruce thermocouple hooked up to a VDO egt gauge.  I'm still wondering about the low EGT.  I hope the measurement is correct.



I'll try to putz with it more this weekend.

[zukgod1]

Ya the temps seem WAY low to me.

I run @ about 800 on the freeway normal cruising.

K24 for referance and I do have a 1.6 but I cant see it being that much differant.

I can hit 1400deg if I push it.

To much fuel not enough turbo.
38psi non intercooled isnt a good thing..

[saurkraut]

When I backed out my governor screw (full throttle stop) on my 1.6td, it really woke up.  Thats what I'll try on the 1.5TD befor I give it more fuel.  I suspect the governor is pulling the fueling back too soon as the rpm builds.

[saurkraut]

Success!  I moved the governor screw (see circled screw in attached photo) a little bit, equal to 2 clip positions on the throttle cable, and it really woke this dinky little engine up.



The initial acceleration is good, but at about half way through the wined up, it sprouts teeth and claws and really pulls, all the way to the fuel cut off.  Max boost is 20 PSI.  Above 65MPH it will accelerate in fifth gear.  I did a four car pass with ease, and when I checked my speed going past the last car, I was doing over 80MPH in fifth gear, with more RPM left to go.
 
AND THE EGT DOESN"T GO ABOVE 750 F !?!?!?!
 
I really wonder about this Spruce thermocouple/VDO EGT gauge set up.   But its not spewing a big cloud of smoke on boost, so maybe its a valid measurement.
 
Well, I'm going to have the opportunity to verify piston condition.  I have a teensy weensy boost leak into the water jacket.  No symptoms at idle or lower manifold pressure.  Who'd a thunk that the 1.5 stock gasket could take 20 PSI boost?  Time for the metal head gasket.
 
 
Oh, and here are the numbers on the pump tag:
 
92935122
0 460 494 134
VE479F2250R134
 
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