Late bosch pump into mk2 turbo conversion

[Retrohowla]

Yes the injectors are blue spot, i am lead to believe you can use 85 ps injectors and it will run ok but not as powerfull as if you use 100ps injectors.
I was talking to a chap the other day who said he bolted turbo gear onto a 76ps and didnt change the pump or injectors at all He seemed to think it ran ok and was allot better on hills than the standard 76ps di.
Ive already started stripping the donor van now, decided i couldnt wait till wednesday the motor is ready to lift out in the morning

[redeemer]

Yes the injectors are blue spot, i am lead to believe you can use 85 ps injectors and it will run ok but not as powerfull as if you use 100ps injectors.
I was talking to a chap the other day who said he bolted turbo gear onto a 76ps and didnt change the pump or injectors at all He seemed to think it ran ok and was allot better on hills than the standard 76ps di.
Ive already started stripping the donor van now, decided i couldnt wait till wednesday the motor is ready to lift out in the morning

I did the same as your friend did! here viewtopic.php?f=3&t=37635&p=348376&hilit=turbo#p348376
Im still with the Cav just opened a little bit, the fueling, and surley it is much better on hills now, that is if before I would give him the 3rd, now it goes in 4th or maybe 5th. Even now it just goes over 65 mph, but not more
Thats why I asked you for the inj pump.

Well I needed to confrm that the bluespots are 100ps because I will order 4 of em soon.

In the meantime , just to remind you, you can buy the rear crank oilseal, gaskets needed etcc, a lot better outside then under the van

[Retrohowla]

Yes indeed, thats why ive already ordered the crank seal and gasket! Gonna do the clutch, cambelt kit and full service at same time

[Retrohowla]

Well annoyed with my local motor factors
They didnt get the pattern rear seal like i asked for, instead i now have a very expensive, gold plated genuine ford item to fit
I always thought they were a good shop but not impressed with that at all

[Retrohowla]

I might add the genuine ford item is the same make as the pattern ones!
Blooomin daylight robbery, if this wasnt my only day i have free i wouldnt fit the dam thing and go elsewhere for it

[redeemer]

What plate seala are you saying about? the one on the rear of the rear oil seal housing? I made that out from gasket material, which you buy for example 1ftX 1ft for only a few Euros which witstands high temperatures, I cut it with a scissors and a round ended hammer for makng holes in place, f you know what I mean.

[Retrohowla]

Oh yes i make all my paper gaskets myself, i was refering to the rear crank seal itself.

[Retrohowla]

Ok guys, the bosch pump is fitted to the 100ps motor now
What do you recomend i set the pump timing to?
Was thinking bang in the middle then work from there once its in the van and can be started
Some hints here would be great, the project is coming along sweet though

[MinorMatt]

just out of interest what factors?

[alanwh]

Ok guys, the bosch pump is fitted to the 100ps motor now
What do you recomend i set the pump timing to?
Was thinking bang in the middle then work from there once its in the van and can be started
Some hints here would be great, the project is coming along sweet though

Start bang on timing and see how you go. Some run fine on this setting others need advancing. I left the timing cover off for a few runs and cold starts and twiddled to get the best of the power and starting. I ended up with about 5 deg. of advance (pump bolts clockwise on the slots)

[Retrohowla]

To get the belt on i had to retard it slightly so im anticipating it needing adjustment.
I think im almost all set now to do the swap, just gotta bolt the box back on and modd the throttle body, make another blanking plate for throttle body also. managed to get all the induction pipes etc gleaming inside and out, should inprove airflow slightly compared to what it was with all that crap from the egr in it

[Retrohowla]

Just out of interest, can i fit an intercooler to this conversion safely?
Only ive been offered one and thought while i was there....................

[alanwh]

I've got one on the drawing boards and have put in a lot of thought but still not 100% there
I'm thinking a high flow one otherwise there is a big trade off with more power but lag, as others have found.
Most difficult bit is going to be routing the piping as it will probably have to to go out and back from the nearside of the radiator to a crossflow type intercooler.The turbo on the DI exits top end too which is a bummer as it makes things doubly awkward.
Don't be tempted by an intercooler with inlet and outlet at the same end, they are crap

[redeemer]

Most difficult bit is going to be routing the piping as it will probably have to to go out and back from the nearside of the radiator to a crossflow type intercooler.The turbo on the DI exits top end too which is a bummer as it makes things doubly awkward.
Don't be tempted by an intercooler with inlet and outlet at the same end, they are crap

But you can turn the turbine housing all way round, if you slack and wd40 the big circlip from behind the housing. then a new location must be found for the wastegate acutator , so the turbo exit points downwards.
Then some elbos etc can be used if the inter cooler has an entrance at the bottom and an exit at the top, maybe hen it is fitted verticaly right behind the radiator , or I had a thought (I am talking about a mk2 i.e plenty of space) to shift the radiator to the drivers side to gain those few inches, and the maybe a slim one could be fitted in the space remaining on the passenger's side
Also alan when you mentioned the Lag, what is it, because of long piping?? the pressure takes more time to build at the in manifold??

thanks

[alanwh]

[quote="redeemer
But you can turn the turbine housing all way round, if you slack and wd40 the big circlip from behind the housing. then a new location must be found for the wastegate acutator , so the turbo exit points downwards.

Yeah thats what I was hoping when i get round to getting to it so that's good news

Then some elbos etc can be used if the inter cooler has an entrance at the bottom and an exit at the top, maybe hen it is fitted verticaly right behind the radiator , or I had a thought (I am talking about a mk2 i.e plenty of space) to shift the radiator to the drivers side to gain those few inches, and the maybe a slim one could be fitted in the space remaining on the passenger's side

I was thinking of one in front of the radiator with a cool modded black mesh front instead of the smilie oval front.
Inlet at the bottom nearside, exit top offside then a U bend to take it back to the nearside

Also alan when you mentioned the Lag, what is it, because of long piping?? the pressure takes more time to build at the in manifold??

thanks [/quote]

It's an interesting one this
Lag is going to be a problem with the Di with an intercooler as its so slow to rev and boost takes a reletively long time to build even without the intercooler.
An intercooler and the piping adds more drag and takes longer for the turbo to pressurise the extra space.

Am hoping the pump I have built with LDA and wastegate controller will compensate a bit for this, though I think long term a VNT turbo might be the only way to get boost coming on tap soon enough.
Time will tell