-
Lucas to Bosch swap?
by
nokivasara
on 23 Oct, 2009 10:45
-
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?
-
#1
by
MJF
on 24 Oct, 2009 07:00
-
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.
-
#2
by
nokivasara
on 24 Oct, 2009 10:10
-
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?
-
#3
by
nokivasara
on 29 Oct, 2009 09:55
-
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?
-
#4
by
nokivasara
on 02 Nov, 2009 09:19
-
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...
-
#5
by
nokivasara
on 03 Nov, 2009 09:20
-
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.
-
#6
by
nokivasara
on 05 Nov, 2009 13:11
-
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.
-
#7
by
nokivasara
on 05 Nov, 2009 13:13
-
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
-
#8
by
gigaz2
on 09 Nov, 2009 16:07
-
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
-
#9
by
nokivasara
on 11 Nov, 2009 05:08
-
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...
-
#10
by
smokeme
on 11 Nov, 2009 15:32
-
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
-
#11
by
nokivasara
on 14 Nov, 2009 09:21
-
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.