well...here are a few other details...minus pics to really get the cummins pump up and going...
The cummins pump in stock form with the gov. assembly, etc. will not work properly...however, if you were going to use the pump on a vanagon, there have been some that have found that the "loaded" gov. setup, like what is used on the bread vans, etc. the 4bt pump came from works well for pulling the weight of the vanagon...
To properly set up the 4bt pump for a car, you need to do the following...
Swap the caged gov. spring assembly from the VW TD pump to the cummins pump, but in doing this you must also swap the control level assembly that is in the pump itself. It is held in by the two "odd", almost 13mm bolts on either side of the pump... the gov. flyweights in my pump at least didn't need to be changed...they were identical to all the VW pumps i had here...
So, along with the caged assembly and control level assembly you need to use the ENTIRE VW LDA. Reason being... the VW LDA and control level assembly you just swapped in the pump meet correctly... If you try using the cummins LDA assembly with the VW control level assembly it has the "finger" for the LDA coming down on the wrong side of the LDA to properly function under boost. You could dismantle the entire cummins LDA, swap in the VW style finger and then reassemble and use it. Only problem is one of the LDA's is more than likely to use a "pressed through" shaft that holds the finger in place...removing it takes patience and being careful reinstalling so that it still seals up. I believe my cummins LDA the finger was in with a screw style setup and my particular VW pump donor was a press in style setup....
Would be nice to use the boost pin that comes with the cummins pumps though...if you have a nice one. It doesn't quiet fit in the bore of the VW TD pump assembly...slightly larger...
Lets see what else. If you have a KSB device on your pump, I'd suggest changing it out...unless you want it. I'm removing mine this winter. It involves removal of the pressure relief valve and the front timing cover, etc. You'll want to do this anyways and also at the same time if you have a TDI donor pump, swap in the TDI advance piston, shims and cover which is MUCH deeper than an IDI pumps advance mechanism. You could "cut down" a IDI VW assembly but it kinda voids out the timing mech altogether and didn't work well for a friend that tried it with his cummins pump.
From there...its resealing, cleaning, etc. In order to use VW timing tools in the pump I ended up swapping the central portion of the hydraulic head at the rear of the pump from a donor TDI pump into the cummins pump as the cummins hole was too large. However, there are adaptors out there for this on the market if you want...or if your handy...i'm sure you can make an adaptor...
Aligning the pump is another deal on the TDI engine. You can either have a 1.6/1.9 IDI sprocket machined out to the size that the cummins pump needs... or, if you want to be able to adjust your IP advance/retard on the fly, you can use an adjustable sprocket from a ALH MKIV style TDI motor... turned around backwards. You'd need to find a core pump with the "hub" that is pressed onto the IP shaft from an ALH pump as well as the sprocket...then with the sprocket you have to flip it around backwards and then have the "hump" on the would be front of the sprocket machined down to be flush with the hub. These are beefy pieces and machining them takes some weight off and then also allows the cummins pump to align correctly with the camshaft and int. shaft pulley. DO NOT take any material off the hub or off the sprocket itself once you remove the "hump" from the front side. With that...adjusting timing is very easy, without having to undo the pump, etc. I'm able to adjust timing in a matter of 5 mins or so...with ease. I see that passenger performance is now selling these as "performance IP sprockets" with the same thing done, bascially machined down on the lathe. Its not expensive to have done at a shop though. I had it done with my machine work to the pistons as well for a really good price, but I did price other shops and they said it'd cost me maybe 30 to have it done....
Hmm...I believe thats enough info to wade through for now... I bumped my thread up as well in prep for winter additions, etc. if you want to look through it...there are alot of pics, etc.
Joe
Topic: I SCORED!! (I Think...) Now How do I convert it???? (Read 9900 times)
