Peugeot expert 1.9 bosch conversion

[lydecker777]

Peugeot expert 1.9 2003
hi all,

ive got a trusty peugeot expert 1.9 non turbo that was a reliable work horse until on MOT day the delphi/lucas diesel pump leaked from the shaft and all over the cambelt..

hmm, after a bit of thought and research it seems alot of people do a bosch conversion to run the veg, after much faffing around ive managed to get a bosch pump off a 1.9 peugeot non turbo..

managed to get it plumbed in,, fired up etc BINGO !!!

except now theres the problem...the pump pulley doesnt line up with the cam pulley, throwing the belt off by 4-5mm..

belt has been refitted, tensioner checked etc..everything ..

im at a loss whats causing this...wrong pulley? a change in pump bracket etc??

please see pics and let me know what you think,

or if theres any guides to the bosch conversion on a dw8 engine?

[sparksie]

While I have not actually done this conversion myself, it is very common over here.
Pretty much everyone understands the Bosch pump, but the Lucas one seems to operate by witchcraft.
I wonder whether you may have omitted a spacer when refitting the pulley.
I'll ask some of the guys who have done it, during the week, and see if any of them have come across this.

[lydecker777]

Hi I've tried everything now ..had pump off today and swapped pump bracket with one off a Peugeot 206 w reg thinking it might be slightly different, however it's still the same issue ....

[kenbw2]

Have you seen my replies to the (many) other posts you've commented on?

Here's the pictures of mine:







Full resolution versions here:

[lydecker777]

Wow, I've just purchased that fuel pump , the other pump was off a 306..xud9 engine ...what injectors are you using? Would 306 injectors fit ? Cheers for the reply thanks Jon

[kenbw2]

I still have the original Lucas injectors. Never had any problems.

Is yours the later DW8B with the ECU?

[lydecker777]

Hi, I believe it is , I've fitted the pump today to discover a throttle spindle leak and although the immobilizer plugs are the same , are they coded to the ECU ? I think I have to de armour mine as I've got no fuel coming through ?

[kenbw2]

Mine definitely needed the immobiliser removing from it. Mine didn't have an ECU but it was matched to the ignition barrel/key chip.

[lydecker777]

Cheers for the reply , looks like thats my next job, did you fit the cambelt? Cheers

[kenbw2]

Fraid not, the garage did everything.

That said, I did end up with my belt like this after a few months



Which looks like mine might have started out like yours. They did fix it and it's been fine since. I'm not sure what they changed though

[ekjdm14]

That looks like it's running off centre due to a damaged/worn tensioner or idler (or even water pump, though that'd likely piddle everywhere). Also I seem to recall a metal guide plate that fits on the crank sprocket behind the pulley to help stop the belt wandering off track, if my memory isn't playing tricks, could this have been omitted on reassembly?

Make 100% sure all the tensioner nuts/bolts are tightened as they can be a bit of a fiddle to reach and if you don't have the spring retainer you're fighting against that too.

Only difference the injectors ought to make is to timing adjustments as there's IIRC about 20-30 bar pop pressure difference so lower pressure injectors would = advanced timing and vice versa

[Pug_XUD_KeenAmateur]

Seems a bit of an over-simplistic suggestion (I've never done this myself)

...but sometimes the obvious can be overlooked

Can you push the belt further on to the Cam Pulley so that its at the NS extreme of that pulley, which might put it within the OS boundaries of the Pump Pulley

Looks from your Pic 2 that there's some room available on the Cam Pulley, perhaps as much as the 4-5mm you're 'short'