Golf 2: Which fuel pump for ARL engine conversion?

Good evening.

My name is Joe, and right now we're building a turbocharger (150+ horsepower, 1.9 TDI) for our Golf 2.

So far, we have everything under control, but we are still trying to figure out the best solution for the required fuel pump.

The starting point is a 1.6-liter carburetor with an older ZE (likely referring to a specific component or system). We have already obtained a fuel tank for a Golf 3 TDI, but we are wondering what the optimal solution for diesel fuel delivery would be in this case.
The internal wiring harness of the old ZE unit leaves us with only a 2-pole cable, which went to the original fuel pump from the carburetor (without an additional pump, like on the 16V models).
We would now be heading towards a VR6 fuel pump, which fits perfectly into the fuel tank of a 3rd generation Golf TDI. However, the VR6 pump unit has a multi-pin connector (the pinout is not yet known to us). We're not sure right now how to best handle the issue with the plugs.

Are there any people here who have completed a 1.9 TDI engine swap in a 2-series vehicle? How did you solve the problem in the best possible way?

"Thank you in advance."

Regards,
Joe

Hello,

First of all, respect if you can pull that off.

Here's the translation:

In a nutshell:
If it fails even when connecting the pump unit, it's best to just stop.
Regarding the fuel pump, to my knowledge, it has a pressure of approximately 0.5 bar, at least that's the information I have for my AJM A4 B5.
And the VR6 pump has a working pressure of 3 or 4 bar .

Connector pins:

1 pump, 1.5mm²
2 conductors, 0.5 mm²
3 fuel level sensors (display in instrument cluster), 0.5mm²
4 strands of cable (pump connection), 1.5mm² gauge.

In principle, the pre-pump can also be completely omitted (the first PD models didn't have one either). The necessary system pressure is generated by the mechanical tandem pump on the engine, which is also self-priming.

I would strongly advise against using a pre-pump for a gasoline engine or a universal pump. These pumps will almost certainly not be able to handle the fuel temperatures produced by a PD TDI engine (up to approximately 110°C at the engine). Therefore, the fuel cooler located on the underside of the vehicle is even more important; otherwise, there is a risk of damage to the lines and/or the tank due to overheating!

Hello everyone,

First of all, thank you for your answers!

Today, I visited someone who has a 1.9-liter pump-injector engine (130 horsepower, 5-speed) installed in their second-generation Golf. Unfortunately, he already bought the car like that, and he couldn't help me with the details.
However, I was able to convince him to temporarily remove the built-in fuel pump .

It has an original Golf 2 fuel tank installed (with the small opening), and a diesel fuel filler neck.
The fuel pump installed is a modified fuel tank unit from a Volkswagen Golf 2 (1.6L). Unfortunately, I can't find any information about the specific pump model, and the markings are difficult to read. I've tried to enhance the existing markings, and I can make out something like "Mezle" or "Mekle," along with the number 456 100 906 0000. The pump receives power through two separate cables. The original connector is then used for the fuel gauge.

Unfortunately, I can't find any information about this pump online, and I'm not familiar with the brand. It would be interesting to know how much pressure the pump generates. Does anyone know this brand?

Anyway, this combination or "hack" works quite well; the colleague has no problems, and everything functions 100%.

If I knew where to get the pump, I could replicate it exactly .

Regards,
Joe.

In the image 5.jpeg, if you look closely and pay attention, you can actually read the VW part number on the right side.
With the poor image quality, I can already see **1,913,051 D.**
hg
Herbert.

Just like the cables simply pass through the lid...
I don't think this solution is good.

191919051D is the number you mean, Herbert .

If possible, I would like to install a fuel level sensor for the injector; I think it should be feasible.
Sure, please provide the text you would like me to translate from German to English.
191919051AP
In older central electrical systems, the fuel tank sensor and the pre-lift pump often share a common ground.

Alternatively, the...
TN 191919051AT
compatible; installed in new central electrical systems, with separate grounding terminals.

What exactly are the arguments against omitting the pump? You can't really overload the ARL/BPX with the weight of the 2-liter container to the point where you get cavitation problems, and if you don't mind the lack of the automatic filter venting feature, then you can just leave it out.

I've already had to decommission some VFP systems at several dealerships because the customer didn't want to purchase a new fueling unit for cost-related reasons. I replaced the pump with a piece of 10mm hydraulic tubing and a strainer from the DB shelf (I can find the part number for you).
The only drawback is that you may have to forgo using a suction pump, and the tank cannot be emptied quite as completely. "Just to be safe, I always slightly bent the fuel level sender and precisely adjusted the 'full' level using VCDS to match the full mark on the display."
So far, everything is running smoothly.

The prerequisite is a fuel system that is airtight (or leak-proof), or alternatively (literally "equally" - a common Russian word used to mean "or"), a check valve in the fuel line.

Hello.

The pump in the picture is from an Audi A6 4B 2.5 TDI .
Part number 16116754762.

Back pressure from 0.5 to 3.0 bar.

Regards, Mpire.

Quote:

Part number 16116754762

The lid in picture 5 does not belong to the pump, does it?
Herbert.

Joe wrote:

The fuel pump installed is a modified fuel tank unit from a Volkswagen Golf 2 (1.6L). Unfortunately, I can't find any information about the pump used, and the label is also difficult to read. Regards, Joe

He took the fuel filler cap from a Golf 2 and "attached" a TDI pump from an A6 to the bottom of it.

...but for cable routing, there are truly "more elegant" and then also more airtight solutions .

Regards, Mpire.

Aaah!
Herbert.