Bosch - Fuelling

[ColinJack]

I will be putting my 'new' turbo engine in this weekend. Hooray!

Have replaced EPIC pump with Bosch manual - set up as per Dieselhead123 instructions (0.68mm advance at TDC)
Removed max fuel tamper ring and added 1/4 turn clockwise to increase max fuel
Screwed mid-range in 2 turns on pump top

I will also be fitting an intercooler, so no doubt these settings are just the start.

There is quite a lot in various posts about setting the fuelling up on these pumps - quite a lot of conflicting info too

What is the tried and tested procedure to get this right? This is a camper, so smoke has to be kept to a minimum to avoid upsetting happy campers and getting banned from campsites ...

[ColinJack]

Suddenly everyone's gone shy

Tim, Andy, Matt?

[MinorMatt]

Havent seen this yet...

As a start point (without intercooler), I wind the top screw in 4 turns from factory and the rear one 2...

I can't tell you where mine is because I can't remember - but I have removed the metering pin from the top of the pump - meaning the top screw is now redundant.

I think the rear screw is in about 1.5 turns at the moment for fuel efficiency and low smoke (without intercooler) but it was probably 3/4 turns in at North Weald (with the metering pin still in place)

Just turn it up until its as smokey as you are happy with, you can also adjust the boost too... more boost with the same amount of diesel = less smoke

Hope that helps a bit?

which pump & injectors do you have?

[ColinJack]

Thanks Matt,

Got orange injectors and a 108 pump. Not sure if you followed this post:

viewtopic.php?f=4&t=129480#p1071877

Which screw effects which smoke (if that makes sense)? Do I start with the max fuel screw - screw in bit by bit until it smokes and then back off say a 1/4 turn and then do the mid range fuelling likewise - say half turn at a time? Or other way around?

How much boost would be safe?

[MinorMatt]

Boost - more or less whatever you can get from the stock turbo

Start with the max fuel (one at the back) until you get the smoke at full power/high revs and then wind up the mid range (one at the top) until you get a slight haze lower down the rev range

[ColinJack]

Cheers Matt,

Will see how we get on.

Colin

[chaezymemba]

hi. unfortunatly i dont have the info that your looking for, HOWEVER, as i have just changed my 2.5 td fly by wire pump for a manual Bosch one. maybe you could help me please?
the question is , how did you wire the new pump?
AND what happens with the twenty or so wires that went into the back of the original managed pump? surely they must be connected to 'somthing'?? many thanks si.

[MinorMatt]

Easy peasy!

In that bundle of wires from the old pump, find the one that has an ignition controlled live (from memory its one of the ones on the top/bottom 2 connectors and is often purple/black). That wire (or an alternative ignition controlled live of your choice)needs to be connected to the injection pump.

Your injection pump will have 0,1 or 3 wires coming out of the back? If its 3, take the shield off the back of the pump and remove the black box. You will be now left with 1 terminal to connect the ignition controlled wire (this is where you connect all bosch pumps to the ignition controlled live no matter how may wires they have).

And all the other wires remain disconnected. They are the communication to the ECU which is now completely redundant and can also be removed.