Lucas to Bosch pump change- IT WORKED!!!

[Infectus-Guy]

Looks like the sudden smoking of my 1991 di must be to do with the injector pump. Its also had tickover problems where it idles fine when cold but high when hot, and with the advantages of the bosch just made my mind up.
So what am i going to need? Throttle cable? What about the pump mounting bracket itself, is that the same?
Thanks for any ideas,
Guy

[bazw]

in an ideal world you will add the cold start so

pump and injector pipes , maybe throttle cable (dont know if they are different), temp sender with in and outlet that mounts in block near oil sender ( there will be a boss for it but it may not be drilled and taped hence ideal world bit but it does work without it ) and wires for it ( runs off diesel cut off solenoid wire ), fuel feed pipe and return from filter housing

thats about it oh and as you have to take the cam belt off a belt kit as they should not be reused

took me an hour and a half most of that being the get the pipes through the manifold bit

hth

[Infectus-Guy]

Brilliant, nice to hear from someone who's done the conversion. Doesn't sound like too much work, i'll have to hunt around for the bits. Thanks!
Guy

[Infectus-Guy]

Just one more question if anyone knows....
Will a bosch pump off a later banana engine fit mine or do i have to get one off the same non-banana engine as mine?
Cheers,
Guy

[bazw]

dont know for sure but the only ones i think that are a problem are the epics with an ecu
i have a banana bosch pump on my pre banana and it works great , as i said only hard bit was getting the pipes through the manifold and keeping them clean while doing it and even then it was not "that" hard

[Infectus-Guy]

i have a banana bosch pump on my pre banana and it works great

Sweet, that's all i wanted to hear! Mind you, i'm gutted as hell coz a month or so ago i towed my mates banana bosch pumped tranny down to the scrappy and let the pump go with it! Off to the scrappy tomorrow then......
Guy

[gemini]

Its also had tickover problems where it idles fine when cold but high when hot, Guy

someones turned the idle speed up to compensate for the cold start not working

cold start raises the idle speed till warm

is the plastic cap still on over the screw at the front of the pump on the engine side

[Infectus-Guy]

Not sure i know what you mean gemini, though i'll have a look tomorrow.

Saw what looked like a bosch pump on a grey (ex BT) transit in the scrappy today. Was a bit confused though as it wasn't a banana engine, it had the more conventional inlet. What age did they stop ones like mine (1991 2.5 di) and start the banana engine? Also what years did they stop the banana engine? I understand the bosch pump will fit (with a few mods for lucas the cursed) any 2.5 from 1985 up to 2000. Is that right?
Cheers,
Guy

[Guy88]

The bosch pump was fitted to the 76ps MK4 & 5 and also on 70ps MK5's

The banana engine is the 76ps. the ones like yours were available with bosch pump up to 2000 and were the 70ps di

[gemini]

70ps with lucas pump was fitted till the end of the mk 4

on mk 5 both banana (76ps) and standard (70ps) used till end of mk5 production with bosch pump

the new generation engine 1992 - 1994 banana with bosch pump was (80ps) usually fitted in the 190 chassis cab

[Infectus-Guy]

OK i got me pump off that ex BT van from the scrappy for £45, it was an L reg so i hope its was the right pump! Here are some pics-





Please tell me i've bought the right thing! It had the same pencil injectors as mine so i think i've got it right. It also had what looked like a water heater in the right hand side of the engine bay, looked like a mini immersion heater with the stuck on foam lagging and a temp controller. Remembered to grab the choke temp sensor out of the side of the block and as much of the loom/wiring as i could. Also grabbed the plastic fuel lines from the filter and the metal lines that go up to the injectors.
Just going outside (in the rain! ) to rip of the old Lucas, probably gonna take more pics and do a little stage by stage writeup for anyone who's considering this mod.
Cheers,
Guy

p.s. The 70ps and 76ps etc, is that an engine type yes?

[Ollie]

A quick question for those in the know about Bosch, I've just changed the engine in mine following a blow up and the new engine came with the same pump as above with cold start, which was fine except it had bugger all power!! and ticked over slow too, so I quickly swapped it over for the on off my old engine which was also Bosch, started fine and powers back, However this one didn't have a cold start valve or any of the gubbins on the block, is this normal? and what diffreence will it make? it has alllways struggled to start on a very cold day, even with really strong spin over, isn it worth getting the "new" pump checked/repaired and refitting it?
By bugger all power I mean just that, as though its only got idle and a bit off idle, no torque anywhere, but revs smoothly without noisses and is if anything too quiet? as this may indicate what wrong with the other pump? anyone got any diagrams for pulling it apart?

[Guy88]

On the later pumps (MK5 on) the cold start is internal

the 76ps engine is the banana manifold type

[Ollie]

in which case, the engine that was fitted to my van was a banana engine (or at least pump) but fitted with the manifold etc off the earlier engine? in which case how is the later (internal) pumps cold start triggered as I see no extra wiring or water feeds to it? would it be beneficial to get it working?

Thanks, and apologies for hijacking the thread!
Ollie

[Guy88]

tbh i dont know how it works. i have a '99 pump on mine and just have the wire to the stop.

The cold start doesnt alter the fueling just the timing so I guess the timings sprung to cold start and the revvs then alter it away from there.