Pump Changeover

[Gohn 62]

on my 205TD I'm changing my diesel injection pump over from Lucas to Bosch 

so far :

- locked it all timed with the cam/pump/flywheel timing bolts etc and removed the Lucas pump

- removed Lucas injectors, injector pipes

- installed new Bosch injectors

- new timing belt (and renewed water pump gasket while down there)

- new Bosch pump in and pump pulley on

 

the next step would be to line up the pump pulley timing holes, put the belt on, roll it around to check and finish up

 

but the Bosch pump pulley won't roll around so can't line up the timing holes ?? 

 

(pump's has just been thru full refurb, it has been sitting for maybe two months including transit

don't know how long it sat on diesel mechanic's bench)

 

no clue what to do and not keen to give up and reinstall Lucas

 so any suggestions appreciated

[welshpug 1,622]

Do you mean the pump wont turn?

[Gohn 62]

yes thats right, the pump wont turn

 

[SRDT 146]

Is your pump bracket drilled and tapped for both Lucas and Bosch pumps? You need to remove the studs and put them on the other set of holes:

 

[Gohn 62]

thankyou both, yes already moved the studs to Bosch positions

 

original problem resolved .  took pump back out and rotated the pulley on the pump with more force, it was just very stubborn

pump back in, timed up, now running 

 

also had to slice off bottom of pump frame as it was fouling my oil filter unit. as a result I can't utilise the throttle damper at present but as seen in pic I have a spare frame that may replace the current one in future

 

further gremlins

- the injector pipes have at least one leak to the union nuts, one on the pump join to injector 3 (counting from flywheel being 1). probably the pipe end has been damaged or something. fixing it next

 

- its not running smooth yet, maybe injector three leak or maybe I'll need to advance the pump a bit

 

- and also there's an electrical plug on the frame of the pump. its black three pin and runs to stop solenoid and the cold start device.

I've bypassed it altogether for now by running a single power wire to the stop solenoid, but would like to connect to the plug properly. I have the correct plug just dont know how to connect what wire etc . any tips from those more comfortable with electrics welcome

 

- last thing of concern was shutting the bonnet !  (the Bosch sits higher than the Lucas). Tested and passed what a relief

[SRDT 146]

What pump did you use? One from the intercooled version of the engine?

[Gohn 62]

I never got to see the donor vehicle (had to take whatever TD Bosch pump I could get)

but as its from here, all the XUD9TD's in australia are the intercooled type, either 306 or 405

its recalibrated for my smaller non-intercooled engine

 

[welshpug 1,622]

The plug is for an advance solenoid, when and how/why its used I have no idea specifically.

[SRDT 146]

If it's from a early XUD9TE it should be the ALFB:

http://405sri.free.fr/Documentation/manuels_atelier_405/405__327-F-05_92_moteur_diesel_XUD9TE-L_principe_de_fonctionnement.pdf

Basically the LFB alter the advance at low loads to lower NOx but with that the engine won't run well when cold so under 60°C it is cut by the solenoid.

[Gohn 62]

cheers chaps

that ALFB seems unnecessary 

anyone know where to get a good set of injector pipes ??

tried everywhere I know and nothing

its peug #157039

 

mines very second hand, worn and with an 'extra' bend here and there

 

 

[SRDT 146]

There should be some diesel shops that can form new ones for you.

[Gohn 62]

yep will do Baptiste

 

also big thanks to Xstian who kindly donated a Bosch pump pulley, its a belter !!

my pump arrived without one and it was hard to confirm if I could use the Lucas pulley on the new Bosch pump.

They are NOT interchangeable. Pump shaft is different guage, so different pulley nut and woodruff key too

 

my braided leak off hose is rubbish. replacing with OE hose which is hard to get but worth it

[Jimarilo 0]

Does anyone have a spare pulley for a bosch diesel pump for an XUD9 engine ??

 

I have swapped the lucas for a bosch and am running the lucas pulley as the recon bosch didn't come with the pulley

 

It runs well but isn't spot on. The teeth alignment are slightly out, so the timing will be as well

 

Cheers

 

 

[Jimarilo 0]

On 1/29/2024 at 7:56 PM, Gohn said:

cheers chaps

that ALFB seems unnecessary 

anyone know where to get a good set of injector pipes ??

tried everywhere I know and nothing

its peug #157039

 

mines very second hand, worn and with an 'extra' bend here and there

 

 

eBay UK  item number:165770841139

[Gohn 62]

thanks jim, I saw those but am a bit sceptical of the quality

 

approached an experienced diesel place over here and they said they no longer make the injector pipes

they used to but the pipes kept failing as they need to be made from high spec piping and fabricated very well

couldn't have enough faith in those pictured to spend the money on shipping

8 hours ago, Jimarilo said:

Does anyone have a spare pulley for a bosch diesel pump for an XUD9 engine ??

 

I have swapped the lucas for a bosch and am running the lucas pulley as the recon bosch didn't come with the pulley

 

It runs well but isn't spot on. The teeth alignment are slightly out, so the timing will be as well

also,

the XUD7 / XUD9 Bosch pump and the XUD7TD / XUD9 Lucas pump all have an M12 shaft, pulley hole and nut is M12x1.75

the XUD9TD Bosch pump has an M14 shaft, pulley hole and nut is M14x1.5

so get a Bosch pulley from an XUD7 or 9 NON turbo

 

[Jimarilo 0]

I used the lucas pipes and just bent them into shape lol

[Jimarilo 0]

Some one somewhere will have a spare pulley for a bosch pump sitting there doing nothing

 

It is just a matter of finding them ......easier said than done ;-)