Performace mechanichal pump for turbo 2.5 Di.

[andypdq]

Tangentially, whilst looking for extra power/ driveability is there any way to clean up the emissions? I'm minded of the current pollution hoo haa along with more emission zones, just wondering if Add blue, as used by lorries, would help. Possibly propane injection?

Do you know what the emissions are like using quality veg oil in the mix?

On the lack of engine braking, is it possible to close the fuel cut off valve on the overrun with some form of control to enable idling etc

The most practical way to clean up smoke emissions is excess air, ie more boost. Emission zones will no doubt be run on the LEZ model, ie vehicle age/type rather than individual vehicle approval. Adblue cuts down NOx emissions afaik.

Veg oil still makes smoke which registers on the smoke (opacity) test, though the chemical analysis of emissions will no doubt be different than diesel

The VE pump supplies zero fuel on overrun if it's set up correctly, cut off valve will make no difference if the pump is working properly. Any problems with overrun and tickover are down to faults within the pump.

[dieselhead123]

As you say Andy, any further LEZ type emission zones are likely to be based on type approval data, not actual emissions produced by a vehicle, modified or otherwise so the 'date of first registration, (in the UK), will likely be the deciding factor.

There was a Q plated Mk4 sold on ebay that showed as LEZ compliant because it was allocated it's Q plate in 2002, TFL assumed it was Euro 3 because the V5 stated first registered in 2002

Once the next pump is on the Chucklebus and tested we will be able to see how it compares with the VW for 'gains', I am sure that the customer is keen to get it on his van.

TIM

[andypdq]

Once the next pump is on the Chucklebus and tested we will be able to see how it compares with the VW for 'gains', I am sure that the customer is keen to get it on his van.

TIM

The interesting thing with the VW is, how easy it is to gain LOTS more power, without excessive smoke. I think it's to do with it being indirect injection, so it has a much longer timing window to get the fuel in, and they are much less fussy when it comes to injectors when compared to direct injection engines.

With standard boost pressure, around 15 psi I estimate we gained 30 to 40% with the pump mods. With max boost increased to 25 psi, I would say it was making double its original power with the full load screw maxed out, no smoke whatsoever once boost was over 20 psi. That's with the original 9mm pump head, it needs an 11 mm head It has no intercooler atm, so it has much more to give.

It was around 70 bhp as standard, I reckon it's way above 120 now, they do seem much easier to tune than direct injection engines.

[Rickbu]

Hi Andy. I've been busy beavering away at this from my own angle, I believe the boost top I have doesn't offer as much movement as the standard torque top, I don't know if this varies between them, anyway I've been machining the boost top to take the transit control levers and allow the same amount of travel as the torque top I'm also going to need to machine up a boost pin to match, by the time I'm finished as far as the pump is concerned it's going be the same inside as a non turbo one, just with the levers operated from boost rather than pump pressure, I believe then I'm eliminating many of the other factors that throw me off the perfect setup. I'm nowhere near finished, I have been taking pictures so I will post them soon

Rick

[Rickbu]

OK got this done now, there are some differences, with my previous setup I had a lot of low and mid range torque but a decent amount of smoke If I floored it ( which I can live with) which faded off to a quite weak top end, now I have a weaker low and mid followed by a much healthier top end. Much less smoke knocking about too. I only just got her back running so still have to fine tune the pump. All in all fairly happy. The only downside is that the control levers I was using before had a separate start lever built in so it gave a nice blip of the throttle on first startup. The transit ones don't have this. Perhaps not a requirement on a direct injection engine.. I'm using a top with the levers on the same side as the transit one so I can use all the setup from that, and the top has been machined to give the same amount of travel as the transit torque top did. It's pretty good

[Rickbu]

OK just been out and had another fiddle, cleaned up the transition from mid to high a bit by taking a bit of pretension of the boost sensor spring. Now it's a more smooth power delivery between off and on boost, another observation, now that I don't have the starting lever I don't get the blip on startup but I also don't get the big puff of smoke everytime either

[andypdq]

OK just been out and had another fiddle, cleaned up the transition from mid to high a bit by taking a bit of pretension of the boost sensor spring. Now it's a more smooth power delivery between off and on boost, another observation, now that I don't have the starting lever I don't get the blip on startup but I also don't get the big puff of smoke everytime either

Hi Rick,

It's great to see someone on the forum messing with pumps, it's commonplace with enthusiasts on other forums centred on other brands, but sadly not on Ford forums. What is the pump number of the pump you have the levers from, and you have a photo of your levers, I've never seen a VE pump without starting levers. You may have an over long governor sleeve from your original IDI pump which renders the starting lever inoperative.

[Rickbu]

Hi Andy, I was running the control levers ( the part that moves the sleeve + the part that pulls on it with the governor spring from the Isuzu pump, it's that which had the starting levers and used to give me a quick blip of throttle and smoke every start, now I'm running a totally different top part which had the hole for the arm in the same place as the original transit one so I'm now running all the control lever setup from the original torque top transit pump instead, including even that part that pivots on the pin inside the top part ( I drove out the pin and replaced it so that it would match the transit control levers.) I also had to mill out a section of the casting where the sliding pin goes through which runs on the boost pin in order to increase the maximum available travel to match the original transit one, including the start and end positions. All in all I'm fairly happy with it now, 1000 x better than the epic pump. I suppose next step for me will be 130 injectors. I have 100s in at the minute

[ColinJack]

dish washer done it myself

Does your missus know you put diesel pumps in "HER" dishwasher

Braver man than me!

[Rickbu]

This is where I milled out to increase the available travel including machining down the sleeve which takes the small o ring

[Rickbu]

This is the part I had to machine shorter also. The sleeve this holds an o ring and seals against a copper washer to keep internal pump pressure out of the boost top. After that a custom boost pin is needed to take advantage of the extra travel. The torque top gives loads of travel in comparison to a normal boost pin

[dieselhead123]

For those of you watching this thread, our 'Hybrid' pump is now one the Mk5, thread can be seen here;
viewtopic.php?f=27&t=92701

A short 'test run' has shown that the fitting of an LDA top is definitely beneficial and significantly reduces 'off boost' smoke. Those members running N/A pumps on their turbo Di's will definitely benefit from this.

The increased fueling this pump offers, approximately 23% increase in 'capacity' over the stock N/A pump provides a noticeable increase in mid range 'punch'.

Andy, you will be pleased/surprised to learn that the 'top end rpm' problem you thought might occur does not appear to have surfaced
Although I think I should invest in a 'genuine' FORD fuel filter to be sure

TIM

[andypdq]

The increased fueling this pump offers, approximately 23% increase in 'capacity' over the stock N/A pump provides a noticeable increase in mid range 'punch'.

Andy, you will be pleased/surprised to learn that the 'top end rpm' problem you thought might occur does not appear to have surfaced
Although I think I should invest in a 'genuine' FORD fuel filter to be sure

TIM

It's amazing what you can learn about modifying fueling systems, if you frequent Cummins, Peugeot, VW and tractor pulling forums. After a few more tweaks, the VW is now peach

[andypdq]

Fitted one of these to Bulletguy's camper last week, 100 HP brown spot injectors, no intercooler, she goes well. He's off for a flit around Scotland in the next few days, so hopefully you'll have an unbiased report on performance and fuel consumption shortly.

[Altransit]

Sounds