Lucas to Bosch swap?

[nokivasara]

My dad has a Escort Van with a Endura -DE 1.8TD engine and we just can't get it to run like it's supposed to. I'm ready to give up on the Lucas pump and swap in a Bosch instead.

This has probably been done quite a few times already so I wonder if there's a write-up on it somewhere?
Is it a straight swap or do I need to make brackets?
Do I need the hard lines too or can I use the ones in the van?

[MJF]

Try find 1,8NA Bosch pump and addd LDA. Should be pretty much bolt on. If you can read finnish, www.holysmoke.fi have some discussion of it.

[nokivasara]

Thanks for the link, I found some threads about this and it does look like it's an easy swap!
The hardest part for me will be to find a Ford 1.8 n/a, Ford diesels are not common in Sweden and most of them are TD's...
Do you think a Bosch IP from a VW 1.6 or a AAZ would fit?

[nokivasara]

I have managed to find a Bosch IP from a Escort n/a 

I bought it unseen and it's on it's way now, I'll have it by tuesday. I really hope it is in good shape and not in need of a rebuild...
I'll post pictures of the swap when I get to it.

What should I do with the immobilizer wires? Just leave unconnected?

[nokivasara]

Got the IP today, I hope it really is from a n/a Ford. The cold start (fast idle?) seems to be electrically operated and there is a valve on the other side of the pump that I'm not sure of what it is. I think it is for timing adjustment. It's wired to the stop solenoid 

The throttle wire fitting is on the wrong side of the IP compared to the Lucas IP but that should be easy enough to fix.
There's a valve on the throttle lever, looks like a EGR microswitch but it has 2 vacuum line fittings! I wonder what that is?
I did not get the sprocket, I hope I can fit the sprocket from the Lucas...

[nokivasara]

I didn't get far with the swap today, took off the cam belt cover, put the engine in TDC, unbolted the IP sprocket and found out that the IP screws are T40. One of my torx bits is broken, guess which size?
T40 of course...

With 30km one way to the nearest tool shop and very little time on my hands I decided to put it all back and continue some other time.
The IP was quite a bit retarded so it wasn't all bad, I aligned it as good as I could and now the car starts much better.

Does anyone know how the electric cold start mechanism is supposed to work? It's wired to the shut off valve.
You can see it in the top picture in the post above this.

[nokivasara]

The Bosch IP is in 
I only took a few pics 'cause the swap is is very straight forward.
I didn't get the throttlewire mount with the Bosch IP so I had to make one, and the rear mounting bracket is completely different on the Lucas so you need that part from the donor car.
I got a rear mounting bracket when I bought the Bosch pump but it didn't fit without some modification, I had to remove a bit to make it fit.

Lucas rear bracket:


There's 2 timing belts on these engines, one for crank-cam and the other for crank-IP. The Lucas IP sprocket fits on the Bosch IP, timing is adjusted by loosening the 3 13mm screws on the sprocket and turning the IP shaft. Of course the locking pin and cam lock are in place during adjusting.

[nokivasara]

One more thing:
How do I bypass the immobilizer?
I thought I only needed a new wire for the shut off valve but apparently the immobilizer also cuts out the starter...



EDIT: Got it sorted, took out the immo/shut off valve from the lucas and hid it under the bonnet and rewired the Bosch shut off valve. The ECU thinks it's still in control 

[gigaz2]

I did that swap on a Renault Express (rapid) 1.9D
in my case the injectors are also different from lucas to bosch, but it worked fine.

the opening pressure on the lucas injectors are lower

[nokivasara]

Yes, the pop pressures are different but I don't know how much.
I would like to see the specs of both sets of injectors, Lucas TD and Bosch n/a, but I can't find them anywhere...

[smokeme]

sorry for the thread hijack but my problem is similar 

i'm getting info together to swap out a lucas epic on a fiat 1.9D for a bosch

i think i should be able to get a 1.6TD pump on there with a bit of hacking. My problem is the injectors, anyone know if the bosch injectors will fit where the lucas ones are, i mean are they a direct swap or do they have different sizes etc..

thanks

[nokivasara]

sorry for the thread hijack but my problem is similar 

i'm getting info together to swap out a lucas epic on a fiat 1.9D for a bosch

i think i should be able to get a 1.6TD pump on there with a bit of hacking. My problem is the injectors, anyone know if the bosch injectors will fit where the lucas ones are, i mean are they a direct swap or do they have different sizes etc..

thanks

It seems to work well with Lucas injectors and Bosch IP on the Escort, just had to time it by ear and run it more retarded than I would have with Bosch injectors.