MTDi pumps coming very soon

Hi all, I've been doing a lot of research regarding fitting mechanically operated fuel pumps to TDi engines , far from happy with the outcome from what people were saying about their MTDi setups,

this left me with only one option , With a lot of help from a local Bosch specialist and a good friend that works in design and development at Cummings engines , being shown most types of dismantled Bosch pumps non seemed to meet the specified specifications ,wrong profiled camplates giving wrong lift and duration ,wrong dimensions for rotary pressure distribution head,wrong diameter spindles ,, wrong delivery pressures ,
    I found that I could nearly get the correct parts from many differently designed Bosch pumps to build one MTDi pump this gave me the specific part numbers and were ordered in with shims to take up the ultra fine tolerances which is said that just the heat from my fingers would make some parts not fit so at great expense with tools assembly/disassembly jigs means that I can now build these pumps to factory tolerances      ,a CNC machining program has now been set up with an engineer that does other work for me ,this will eliminate the use of parts from so many different pumps( 5 up to now ) I'll be fitting my third one this morning ,this one was built yesterday , the early type running at 190bar it took 9 hours to build this was due to parts not measuring up , having to repeat pre assemble measure strip several times , next part to look for is a ( 1.6td ) jx type pump to see if the aneroid device may fit onto the main pump body without to much machine work , from the TDi pumps I've striped three that worked at different pressures these used different internal parts ( more than whats in an engine ) meaning more research for the correct parts needing to be fitted one needed lots less work because of being able to just purchase the correct parts to fit ,
once I've got parts machined up prices for parts/seals/shims I'll be able to work out prices for these Pumps

The first pump that I built ( 03 TDi skoda ) Is for my own common rail conversion the pump is tested it's fitted with a differently profiled camplate/ lighter governor weights with a shorter actuator this will be able to rev a little more but giving much better characteristics at the original governed speed , I've just got the injectors to recalibrate to a specified pressure now ,   

All jokes aside, do you have a target price & spec for what you are producing? Am very interested to see how this turns out.

if full stops were put in place someone might fall off their cloud

Price will depend on the type of fuel pump.
Spec will be to the original TDi pump suplied

The common rail is being converted to MTDi .
I've worked the injectors so that they're in the switched open position by means of removing internal parts .   - these might just need recalabrating to break open at a lower pressure now , if these do not work I'll fit the injectors that came with the pump from a late spec TDi that had a rod through the block

The pump that I fitted yesterday worked spot-on but the fuel lines needed increasing to do a full check.
I had an appointment else where with a common rail set-up, so did not have time to fit fuel pipes that day .


Edited by famous phil - 18 Apr 10 at 00:02

Hi Famous,

how come you dont just use a landrover pump? Mine works great, and you are going to a heck of a lot of trouble to make a standard spec pump, when you could make more power with a landrover unit.

That milling machine looks a bit dirty, will they remove all the swarf before you put the pump in there?

rolo wrote: Why not leave the cr pump and fire the injectors via a petrol dizzy in the vac spot?

This goes against E.M.C electro magnetic capability , which I was looking into ,   The later VW tdi does not seem to have the lower vac port . I'm just building one for my own use ,I can buy low millage common rail engines without high press pump and injectors for £100 because they don't go wrong

Right here's a good question- If your stuck in the desert with a TDi powered vehicle and the ECU malfunctions due to component failure, With no outside communication and only supplies to last three days . rescuers will take at least 10 days to find you-
1 your either with one other person and still have battery power to turn the engine over
2 are with enough people to push start the vehicle and have no electrical power
What would you do ??????????? chocolate chip cookies to the person with the best answer

monkey magic wrote: Hi Famous,how come you don't just use a landrover pump? Mine works great, and you are going to a heck of a lot of trouble to make a standard spec pump, when you could make more power with a landrover unit.That milling machine looks a bit dirty, will they remove all the swarf before you put the pump in there?

Hi,"hec of a lot of trouble" There's more to this than just getting an engine going in a recreational vehicle , this just adds further to my investigations , plus this further development is more of proving a point -so many people said it could not be done , even the many diesel pump specialists I contacted thought it could not be done .
I've seen these early TDi rotary pumps with a remapped ECU and larger nozzles fitted to the injectors making 180+BHP ,   

Do you still have the original TDi pump ? what aneroid device does the pump fitted to your vehicle use ?

As I said I've done much research , looking at dismantled pumps , after seeing the internal parts , differences like governors , camplates fuel distribution head The first MTDI pump I built works at = 1st pulse 220bar 2nd 300bar ,,,,, I bolted the disco pump ( 200bar ) to my test-bed with these later spec TDi injectors , these only injected at the lower pressure , The discovery pump will only work on a four cylinder engine , Whats the choice when trying to get a 5 or 6 cylinder engine to run correctly !!

The fuel pump does not go into the milling machine as a built unit swarth is not a problem to what is machined then polished , after this the parts are meticulously cleaned because the slightest particle will ruin the pump in no time    

Edited by famous phil - 18 Apr 10 at 00:07

Anybody with any common sense dosent go into a desert with one vehicle.

russel at syncronutz wrote: Anybody with any common sense dosent go into a desert with one vehicle. If you do you deserve wot you get. As to failure if you travel to far flung deserted areas of the world you should know your mode of transport inside out and have the ability to fix it or the means to get out of a situation. Generally the electronics on a TDI are very very very reliable and there is a built in safe limp mode. Russel

Sorry if you misunderstood , the question was just to picture the scenario , rather than to mention friends of friends lost at war due to an electrical issue ,and through no fault of there own diverted from the rest of the convoy , The military keep pushing for vehicles to meet E,M,C to no avail this is why a lot of the old NAD's are getting rebuilt

Edited by famous phil - 25 Mar 10 at 23:42

Do I get the cookies or not?

Edited by rolo - 26 Mar 10 at 07:32

Hi, I'll answer a bit more in-depth later , the double pulse is to do with the injectors as well as the steep aggressive camplate , the injectors have a light spring for 220bar then a heavy spring for 300bar ,

monkey magic looking through some of your posts your saying your pump (engine) is a hybrid = filled out mounting holes /running different injectors /some having pump mounting plate machined and adjusted fuelling screw and governor mod , it seems as though there's more work on fitting that type of pump "especially if someone wanted one to work correctly"


If an Mtdi pump sells for 3 to 4 hundred then i would say dont bother with the effort involved in doing an e-tdi. But you still have the issue, it's still a hybrid and could be very expensive to repair if it failed ,    This is next to sort out is the new pumps (chassis) code .
The main parts ( in these types of rotary pumps) that pressurise the fuel are not disturbed in the production process , the cost of repair if ever needed , should be less than an electronic pump !
There will be far more people wanting my MTDi set-up than to mess with wiring once the price is established , There's many engines in breakers that could be bought that do not have keys or have damaged missing ECU's/looms . Also I'll have another product that can attach to the electronic pump in case of emergency , it can still be started with no ECU fitted , I've designed this and the parts will be machined soon       

Edited by famous phil - 18 Apr 10 at 00:22

 Still confused over what you are doing. Is it a conversion that operates any vp electronic pump mechanically and also reacts to boost? Or a new version of a ve mtdi as per disco/LT specific to a 1.9tdi? Either can only be a hybrid? Or something else?  

Edited by rolo - 26 Mar 10 at 19:27