Late bosch pump into mk2 turbo conversion

[Retrohowla]

Hi guys, getting all the bits and bobs together for this turbo conversion but i have a question about the pump wiring.
Its a 1999 bosch 686-2 (145) with three wires coming out the back going to a black connector.
How do i wire this into my mk2 loom?
Heres what it looks like if the link works..........

[Retrohowla]

Ok so i had a bit of spare time this eve so pulled the pump apart to see if i could work it out.
Im guessing the three wires were part of an imobiliser system, when i removed the back plate i found a little black box, i removed this and it had one wire coming out the back going to what i assume is the stop solenoid
I removed this whole deal off the back and now guess i just go direct to the solenoid pictured below with my single switched live feed?

[MinorMatt]

yup thats right

the 3 wire bit was for the PATS system attached to the later van. You wont need it and you have discovered the stop solenoid which needs 12v for the engine to run (but I guess you knew that anyhow?)

[Retrohowla]

Yeah i thought so thanks for reassurance, yeah i will just use the same switched live feed from the ignition as is on the current pump
Thanks again

[redeemer]

So what colour is the solenoid wire? I maybe doing this soon if I find a pump.

How about some piccies of the manifold, turbo, inlet piping you used??
I did this but hadn't got the right parts from a later van, so I did everything myself.
Im still running the Cav pump, its not tha powerful, but good on mpg. 32mpg last reading I made.

[Retrohowla]

I will try and get some pics up soon, i may be doing a complete engine transplant now though as been offered a 100ps engine.
Im working nights so it will take me a while till i can get some pics up, the solenoid wire on mine is black, but i have a feeling i put this in myself as my van used to be petrol.

[redeemer]

If you make any plan to sell the 145 pump, just pm me, Im interested.

[Retrohowla]

Sorry i wont be selling the 145 pump as i need it myself but if i come across another on my travels i will let you know.

[Retrohowla]

Im collecting the 100ps engine on the weekend, i believe its still got the epic pump so just wondered if anyone can tell me if im missing any parts for this conversion?

So far i have
1994 100ps engine complete and running in van still
1999 bosch 686-2 145 pump

i understand i need injector pipes yeah? will any do from a bosch pump or do they have to be from a 145?

are the injectors compatible 1994 injectors, 1999 pump?

are the pulleys the same on the epic and bosch or will i need to swap them?

Im going to remove the egr but is there any other vac pipes etc i need to sort out?

i will post pics up as soon as i collect this van im gonna break to get the engine

[alanwh]

Im collecting the 100ps engine on the weekend, i believe its still got the epic pump so just wondered if anyone can tell me if im missing any parts for this conversion?

So far i have
1994 100ps engine complete and running in van still
1999 bosch 686-2 145 pump

i understand i need injector pipes yeah? will any do from a bosch pump or do they have to be from a 145?

are the injectors compatible 1994 injectors, 1999 pump?

are the pulleys the same on the epic and bosch or will i need to swap them?

Im going to remove the egr but is there any other vac pipes etc i need to sort out?

i will post pics up as soon as i collect this van im gonna break to get the engine

Original EPIC pipes will fit but you have to bend the nuckles of two of the pipes to mate up to the pump, wrap a rag round the pipes and use mole grips
Turbo Injectors will be fine
Pulleys fine
Just disconnect vac pipe to EGR, you can put a blanking plate over the EGR to inlet manifold if you like and make sure throttle butterfly is either tywrapped in the open position or pop in a self tapper between the lever and throttle body to be doubly sure

PS you'll need a rear pump to block mounting bracket if you don't have one with the pump
Oh and make sure you use a new belt and tensioner, the Bosh pump puts much more load on the belt than the EPIC

[Retrohowla]

Thanks Alanwh, thats brilliant, there seems to be conflicting reports about compatibility of post 95/post97 injectors and pumps but i think im gonna go with this then and see what shes like.
With regards to the back pump mounting bracket, do you have a pic of one as im not sure what you mean?
Is it the gold colour plate that i removed to get to the pats unit on the back of the pump?

As for new belt and tensioner, that will be done as a matter of course whenever i buy a motor, cant even trust sevice book stamps these days.

Do i just get a standard cambelt kit to suit the van the engine came from yes? Ive been told later engines had a wider belt to cope with the high pressure of the later bosch, is this correct? If so would it pay to get a later kit with my pump being from a 1999 van?

Sorry so many questions only i wanna be fully gen'd up before i collect the motor as i will be chomping at the bit to get her fitted

My mates in thier T4's and Ducatos wont know whats hit em

[alanwh]

I think you're pretty much stuck with the thinner belt if that's the one thats fitted on the turbo, otherwise you've got the added probs of changing all the pulleys to post July 97 to suit, which I've never heard done before tbh.
mebe some of the other lads will know
Don't hold me to it, but I should think you'll be ok though just as long as you shorten the changing intervals and put on a Gates belt and it's not the end of the world on these engines if the belt does give up the ghost as it will only be pushrods and rockers
The earlier 100PS Injectors should be fine, the standard pop pressure of the 145 pump will be lower anyhow. you can always upgrade to the later blue spot if you get too much smoke.
Yep the gold coloured thing is the rear mount bracket so that's sorted

[Retrohowla]

Belt wise i think your right yeah, i seem to recall last belt i did the crank pulley is flanged and the belt was a good fit in between the flanges so thinner belt it is as i dont have the post 97 pulleys

I norm do my belts way before the years or miles anyway as im paranoid about breakdowns, as for make of belts i always go gates like you say, no point going less quality for the sake of a tenner.

Good news on the back pump bracket!

With regards to pop pressure of the 145, i was lead to believe it was higher than the lucas?

many thanks for all the info

[Retrohowla]

Ok well the 100ps motor is in my posession
It seems to pull well although i dont have anything to compare it to, i cant rip it out of the branflake factory of a van till weds though so will prob have many more questions from wednesday onwards

[redeemer]

So good luck then!
What injectors are you going to use ? or what colour the 100ps ones are ? blue?
And
maybe this one for alanwh
what injectors complement the 145/6 pump??, as Im still hunting ebay for one complete with injectors maybe, but postage to here (tiny Malta ) cost a lot