Announcement

Collapse
No announcement yet.

T4 : Battle Across Time (2010 to present)

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Originally posted by regcheeseman View Post
    Calipers? What do you need them for -
    Need to check the turbine and compressor wheels against the KKK spec.

    Comment


    • Originally posted by Activ8 View Post
      Need to check the turbine and compressor wheels against the KKK spec.
      Fair enough - thought you were still on about the pump work.

      Comment


      • Originally posted by regcheeseman View Post
        Fair enough - thought you were still on about the pump work.
        Originally posted by Fruitbat View Post
        Not very accurate though.
        0.02mm up to 100mm, 0.03mm to 150mm good enough for the turbo but not the pump.

        Comment


        • Heres the best K24WC turbo compressor map I can find for the standard compressor wheel.
          Well it is from the 80's and 90's.
          The billet enhanced version will create a taller and broader graph.

          Click image for larger version

Name:	K24WC Compressor Map.jpg
Views:	1
Size:	65.5 KB
ID:	266894

          A lot of the "old skool" German turbo manufacturers information are in m^3/s at 20degC, see above.
          Other manufacturers like Garret use lb/min. You can use the plots to calculate the boost graph and bhp targets.
          Use a conversion factor of 162.04 to convert between the metric and imperial displays. (e.g., 0.25 m^3/s * 162.04 = 40.51 lb/min).
          As a rough guide 1lb/min airmass is equivalent to 10bhp , so 40.0 x 10 = 400bhp (potential)
          Last edited by Activ8; 17 April 2019, 11:28 AM.

          Comment


          • Identifying Bosch VE Type Injection Pumps

            The Volvo D5252T uses this pump VE5/11E2300L649 / 074 130 109H or 074 130 110M / Bosch Part# 0460 415 990

            VE - denotes the pump type , in this case Distributor
            5 - denotes the number of cylinders, in this case 5
            11 - denotes the pumphead plunger diameter in mm
            E - denotes Electrical Governor , F denotes Mechanical Governor
            2300 - denotes the governor controlled RPM number
            L - denotes the pumps direction of rotation
            649 - denotes the production serial number

            Bosch VE High Pressure Pump bodies fitted to 5 cylinder Engines

            AJT - VE5/11E1750L714-1 074 130 109B or 074 130 115B or Bosch 0460 415 983
            ACV - VE5/11E1750L714 074 130 109B or Bosch 0986 440 562 or 0460 415 526
            AXG - VE5/11E1750L777 074 130 109R or Bosch 0986 440 571 or 0460 415 985
            AHY - VE5/11E1750L777 074 130 109R or Bosch 0986 440 571 or 0460 415 985

            So, the governor controlled rpm on the pump of the 2.5TDIs' is 1750. This equates to 4375rpm (1750 x 2.5) at the engine.
            The Volvo pump however is greater at 2300, equating to 5750rpm (2300 x 2.5) at the engine.

            Big deal you mutter but for power thats the difference between the 2.5 generating 233bhp and 298bhp at just 1 bar of boost! (assuming 100% efficiency)
            Or, 350bhp and 447bhp at just 2 bar of boost! (assuming 100% efficiency.)

            And for the AAB and AJA owners, (one of these but depends on the year of manufacture)
            VE5/8F2100L358 / 0 460 485 003 / 0 986 440 242
            VE5/8F2100L453-4 / 0 460 485 009 /
            VE5/8F2100L545 / 0 460 485 017 / 0 986 440 242
            VE5/8F2100L545-5 / 0 460 485 021 /
            VE5/8F2100L525-5 / 0 460 485 022 /
            VE5/8F2100L632 / 0 460 485 024 / 0 986 440 252
            VE5/8F2100L545-6 / 0 460 485 032
            VE5/8F2100L545-3 / 0 460 485 033 /
            VE5/8F2100L752 / 0 460 485 037 / 0 986 440 253

            The ABL owners,
            1999 -2004 : VE4/9F2100R471-3 / 028 130 115 L / 0 986 440 257
            1996: VE4/ 9F2250R328-5 / 068130110B / 0 986 440 135
            1991-1994 : VE4/9F2100R471 / 028130108 / 0 986 440 141 / 0 460 494 308
            There are others but you can look those up yourselves!
            Last edited by Activ8; 20 April 2019, 07:32 AM.

            Comment


            • Had the pump body in the parts bath for a day or so and it's cleaned up nicely. In the day light I can see internal wear around the roller ring & bearing pins...

              Reg, any advice?

              Last edited by Activ8; 18 April 2019, 05:42 PM.

              Comment


              • Cleaned up the EDC cover, not quite polished but it will do! The ocd voice is telling me to do more....

                Comment


                • Test rebuild started this aft. All back together in less than 20 minutes including tea breaks. The only info I need after the dry rebuild is the torque settings for the two screws that secure the feed pump assembly. When rebuilding I may fill a syringe with diesel to lubricate the moving parts as I'm rebuilding

                  Next order a full gasket set and strip again for a more thorough clean.

                  Note: I didn't touch , adjust or change the regulating valve as this sets the internal pressure of the pump.

                  Comment


                  • The next stage involves fitting the camplate. This is where you can be 180° out - correct Reg? The lugs of the camplate fit here -



                    Note the plunger drive pin (red) on the camplate, the pin should align with the woodruff slot on the drive shaft, set at 12 o'clock on the pump body. Apologies my pics need turning 180°!



                    Incorrectly fitted.

                    Last edited by Activ8; 19 April 2019, 12:13 AM.

                    Comment


                    • Originally posted by Activ8 View Post
                      Reg, any advice?
                      Yep - bolt it together and stop being a gurt fanny

                      Originally posted by Activ8 View Post
                      When rebuilding I may fill a syringe with diesel to lubricate the moving parts as I'm rebuilding
                      Dont bother - red grease for sealsd and a drop of engine oil for assembly and plain grease to hold those bits in place that fall out when you try to put it back together.... you'll find out.

                      Originally posted by Activ8 View Post
                      The next stage involves fitting the camplate. This is where you can be 180° out - correct Reg?..... the pin should align with the woodruff slot on the drive shaft, set at 12 o'clock on the pump body.
                      Yep - That's right.

                      The roller assy isn't the same as the TD pumps so you dodged a potential pitfall there.

                      Comment


                      • Originally posted by Activ8 View Post
                        [

                        So, the governor controlled rpm on the pump of the 2.5TDIs' is 1750. This equates to 4375rpm (1750 x 2.5) at the engine.
                        The Volvo pump however is greater at 2300, equating to 5750rpm (2300 x 2.5) at the engine.

                        Big deal you mutter but for power thats the difference between the 2.5 generating 233bhp and 298bhp at just 1 bar of boost! (assuming 100% efficiency)
                        Or, 350bhp and 447bhp at just 2 bar of boost! (assuming 100% efficiency.)

                        Assume what you like - it's all pie in the sky theory. Scientists are not engineers.

                        But yes - that's why I've been doing gov mods for 20+ years.

                        I'd love to know how the gov speed is regulated by the TDI pump as the spring assembly I normally modify doesn't exist in the TDI pump - you could machine and balance the weights in the governor - as that's the only other variable I can imagine.

                        Comment


                        • Originally posted by regcheeseman View Post
                          Assume what you like - it's all pie in the sky theory. Scientists are not engineers.

                          But yes - that's why I've been doing gov mods for 20+ years.

                          I'd love to know how the gov speed is regulated by the TDI pump as the spring assembly I normally modify doesn't exist in the TDI pump - you could machine and balance the weights in the governor - as that's the only other variable I can imagine.
                          According to Bosch the pump is good for 2500rpm or 6250 rpm at the engine.

                          I checked last night - the EDC , pump head assembly are different on the Volvo pump. Looks like the G149 has a broader range/sweep compared to my ACV spare. This ties in with Volvo maps too plus there's a little spare in the map for broadening it a little further.

                          Comment


                          • A little update from a brief spell in the garage this morning.

                            I took the diesel pump pulleys off to compare them just in case theres any belt, timing mark or physical timing differences. To the naked eye they look identical 33 tooth with what looks like identical timing marks. The Volvo D5252 was slightly heavier at 3.421Kg compared to the ACV 3.407Kg.

                            Comment


                            • I also compared the physical characteristics of the EDC (Electronic Diesel Control) and their governor pins. Both are stamped '44' and look identical ( I thought the pin may be positioned differently ) , from underneath they're identical although they're marked 6.1 on the ACV and 9.1 on the D5252T. The Bosch part numbers are different with the head parts and governors identifying different components and part numbers. The timing pistons are identical. The main bodies are the same.

                              Last edited by Activ8; 19 April 2019, 05:33 PM.

                              Comment


                              • Interestingly, whilst having an early beer in the sun I spotted this table in a Bosch manual identifying the properties and characteristics of their diesel pumps.



                                Whats interesting is the comparison between the manual governor VE pump models and the later Electronic Control version, in essence "zip" !
                                Both can deliver 70mm3 of fuel. So AAB and AJA owners take heart that the potential is there!
                                Last edited by Activ8; 19 April 2019, 06:07 PM.

                                Comment

                                Working...
                                X