coyote
Part of things
Posts: 96 
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as a former continental-employee i have to tell you(and all others) that yellow and red dots have nothing to do with the balancing of the tyres. it is just an end-conrol-mark...
i know. the myth will never die.
but nice work anyway!
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Don`t eat yellow snow!
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Apr 25, 2019 12:58:41 GMT
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as a former continental-employee i have to tell you(and all others) that yellow and red dots have nothing to do with the balancing of the tyres. it is just an end-conrol-mark... i know. the myth will never die. but nice work anyway! I think you missed the point, He's using it to show the tire is moving around the rim. |
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1988 Mercedes w124 superturbo diesel 508hp
1996 Mercedes s124 e300 diesel wagon
1990 BMW E30 V8 M60 powered!
1999 BMW E46 323ci project car
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coyote
Part of things
Posts: 96
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Apr 25, 2019 20:28:29 GMT
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you may be right .
sorry for that one.
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Don`t eat yellow snow!
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Jul 22, 2019 10:25:52 GMT
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Fuel Lift Pump Upgrade.
If you are not familiar with these engines than I should mention that there are normally 2 fuel pumps on old diesels. One pump delivers fuel from the fuel tank to the fuel injection pump and the other injection pump does all the clever high pressure metering stuff down the lines to the injectors. Traditionally the pump that supplies the fuel to the injection pump is called a Lift Pump (often an old diaphragm/piston pump that runs off a cam in the injection pump) and the main pump is technically the Injection Pump or IP. My IP is souped up and can flow 250cc of fuel in 1000 revolutions per cylinder. This is A LOT OF FUEL and in reality it’s turned down.
I removed the old mechanical cam driven lift pump when I built that car and replaced it with a Holly black, very high flow but only about a bar of fuel pressure. I have suspected that the pump can’t keep up with the IP at higher revs as its located under the tank and pushes the fuel through an estimated 10’ of 8mm line, where its ability to supply the quantity of fuel required has diminished. Well that’s my theory…
The reason I think this is happening is that by reviewing video evedence the smoke initially is very visible (as I have the IP ‘turned up’) and as the revs rise under what the exhaust clears up. I suspect this is fuel starvation, hence leaning out the engine.
What I want to happen is to get the right amount of fuel so that the engine gets the fuel it needs and no more – and hopefully less smoke. If I get this right I’m hoping I can turn the pump down and get less initial smoke and as the revs rise the mixture will be maintained as the lift pump can keep up, power kept and less smoke.
That the aim of this upgrade.
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Jul 22, 2019 10:48:00 GMT
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Holley Black under the car - fuel pump under-tray removed.  Removed from the car - note the fabricated hanger to utilise the original fuel pumps rubber hangers that work beautifully to reduce N&V  |
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Jul 22, 2019 10:56:21 GMT
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These are the original fuel pumps, the large loop held a filter and the small one an accumulator.  |
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Jul 22, 2019 14:29:49 GMT
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The pictures above show the Holley in its rubber hanger under the car. When the car was petrol it had 2 fuel pumps in series also pictured – initially I was going to use these however they are 30 years old and I thought if I’m going to do this I might as well do it properly and buy the ubiquitous motorsport Bosch 044.
The plan was to get that to pump fuel to the engine bay, through a filter, into the IP and then regulate the pressure on the return side with a 1:1 rising rate FPR.
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Last Edit: Jul 22, 2019 17:01:44 GMT by maxypriest
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Jul 23, 2019 12:40:07 GMT
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So this arrived from Ebay - £145 and I made a bracket to enable me to hang it under the car to keep the noise down. When I tested this arrangement it really works well – you can hear it but zero vibrations and no excessive noise. Perfect.
The pump holder was a £6 ebay item and its blooming perfect! The rubber fits really well and holds the pump firmly.
Highly recommended!!
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Jul 23, 2019 12:45:12 GMT
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From eBay  Immediately I got the drill on it and removed the one way valve....   |
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Jul 23, 2019 12:48:06 GMT
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Then I made the bracket to suit the £6 pump holder and it ended up looking like this  And mounted under the car and connected up it’s like this   |
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Jul 23, 2019 12:51:44 GMT
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As the old electrical system was set up for 2 pumps I simply doubled up the connections to make way for the 16A ish of full current load. P clipped the wiring a bit and then all sorted. No leaks either :-)   |
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Mounting the FPR - I spent ages trying to find a location and for this and eventually settled on a place that already had 2 mounting holes redundant from the old EZL unit from the k-jetronic (long gone...). So I modified the bracket and it ended up looking like this - nice solution.  And mounted it in the engine bay like so...  |
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An over view of under bonnet fuel system
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Jul 26, 2019 12:10:03 GMT
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Man this is cool. Love the combination of a big barge with a honking great turbodiesel.
You've got me hankering to get started on my XJ40/330d swap (and questioning whether an OM606 would be better...)
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Jul 30, 2019 14:37:11 GMT
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Man this is cool. Love the combination of a big barge with a honking great turbodiesel. You've got me hankering to get started on my XJ40/330d swap (and questioning whether an OM606 would be better...) Someone has done a BL goose poo coloured OM606 / XJ6 (tombstone rear lights) and its an absolute beauty, there are some vids somewhere.
Of course an OM606 would be better ;-)
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Jul 30, 2019 14:40:02 GMT
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Not exactly news to anyone… however the Bosch044’s reputation appears to be well deserved. It’s a beast.
Firstly the hanger design works beautifully – the pump is much-much quieter than the old Holley Black, low noise and no vibrations into the cabin.
Secondly the regulator in the return line works… sort of. The aim was 1-4 bar of fuel pressure depending in the boost, what I have is 2-5 bar of fuel pressure. What I believe is happening is that the 044 is producing more fuel in pressure and volume than the Malpassi RR FPR can cope with, hence the lowest working regulated FP I can get is 2 bar at idle. While not what I was after, I have to say its working faultlessly within this pressure range.
Thirdly the fuel pumps adjustments really work well now, I can adjust the pump from being completely smoke free to literally turning ‘day to night’.
On the old settings where the Holley Black was clearly struggling with fuel pressure (to be clear – that’s not its forte anyway) the ‘on boost smoke’ now that the fuel pump is operating with the correct lift pressure was absolutely comical. Funny as it was the first thing I did was pull over and adjust the pump down… and I repeated this step several times too, the old settings were voided by the upgraded FP.
No smoke is easily possible, however at this setting it does take ages for the turbo to spool. What this engine needs is a spot of over fuelling, and its this that really speeds the HX40 into life. Then the on boost fuelling takes over, ‘warp drive’ is enabled and it’s that stage I’m at - boost fuel fine tuning.
What is interesting is that with no smoke, if you drive the engine past 3,000rpm the turbo will spool up and provide a good bit of smoke free, low EGT shunt to the red line - almost like having a laggy race cam. It is however not much fun; I suppose because the low down thrust is missing. Interesting.
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Paul Y
Posted a lot
Posts: 1,951
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Jul 30, 2019 22:25:03 GMT
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Might I suggest a whiff of N2O? Or even a little LPG to continue your Kirk’esk escapades? Nice work. P.  |
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Turns out that duct taping an iPhone to your steering wheel is not the best way to mount it, anyway gives you the flavour of 181.2mph over a standing mile - ‘dead chuffed’ does not begin to describe how happy I am with this result. Lots of nice pics on their way and a fly past YouTube vid too.
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My god that's astonishing. Great work
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