TD04 project.

[ADV_93]

So i bought a TD04 about a week ago off Ben. Got a rebuild on it (don't ask plsssss) and finally today got it bolted on. This is for my on-going project which includes the usual TD04, Bosch and FMIC setup.

Fitted TD04 and i'm running it with a Lucas pump. The car is mental. As in, there's no boost until about 3.5k and then it hits 2 psi (boost controller is wound all the way down atm, it's only a safeguard, will increase it soon), and it smokes like a b******d! Also i've got my Lucas pump about 1/4-1/3 of a turn.

Does anyone actually have any experience with a TD04 and a Lucas pump? Just want to have the car working a bit better until i get a Bosch setup for it. So any advice would be appreciated! Pictures to follow!

[toseland]

out of interest, what boost controller do you use?

[ADV_93]

Bleed type. I do have a ball and spring also.

[306pc]

More psi to burn fuel/stop the smoke screen.

[Mattcheese31]

More psi to burn fuel/stop the smoke screen.

this . . ..^^^^^ . .

[bigcheez2k3]

More psi to burn fuel/stop the smoke screen.

this . . ..^^^^^ . .

What they said.

TD04's spool later than the standard turbos so you will have to rev it more than before.

[bashbarnard]

Bosch would be better

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Plus more psi

[Dave]

Your lucas is probably running out of puff as soon as your td04 is coming on boost, so i'de imagine theres about a 400rpm power band on that lol. Get your bosch on

[ADV_93]

Your lucas is probably running out of puff as soon as your td04 is coming on boost, so i'de imagine theres about a 400rpm power band on that lol. Get your bosch on

Mate i'm trying haha!

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Your lucas is probably running out of puff as soon as your td04 is coming on boost, so i'de imagine theres about a 400rpm power band on that lol. Get your bosch on

Mate i'm trying haha! Was thinking of just winding the lucas max fuel until it won't go anymore, see if that makes any difference? The car is fine to drive at slow speed/low rpm.

[silverzx]

Ran my 1.9 205 on Lucas/TD04L for a good 8 months or so.

Span the wheels in the wet in 2nd/3rd.

Was pretty nippy, had no rev counter so can't comment on lag etc.

I had the older style Lucas if that makes any difference.

[ADV_93]

Ran my 1.9 205 on Lucas/TD04L for a good 8 months or so.

Span the wheels in the wet in 2nd/3rd.

Was pretty nippy, had no rev counter so can't comment on lag etc.

I had the older style Lucas if that makes any difference.

What was your fuelling/setup with it? If you can remember! I'm not certain on the differences between the pumps.

[jammapic]

You should be able to get at least ~140-150hp of diesel in there on a lucas... Wind the main screw in all the way, the back it off quarter of a turn (it probably won't run with it right in, some do, some don't) and then wind the smoke screw right in, and wind it out until you get a sensible spool up / not too much smoke off boost.

JP

[Ruan]

Sounds to me like you've got a chronic boost leak or the wastegate isn't shut fully.

[Dave]

Yeah as Ruan said, you've probably missing alot of air if its chuffing like f*ck after 3.5k. I know some td04's does do anything untill past 3.4k

[ADV_93]

You should be able to get at least ~140-150hp of diesel in there on a lucas... Wind the main screw in all the way, the back it off quarter of a turn (it probably won't run with it right in, some do, some don't) and then wind the smoke screw right in, and wind it out until you get a sensible spool up / not too much smoke off boost.

JP

Main screw being max fuelling and smoke screw being boost compensator?

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Yeah as Ruan said, you've probably missing alot of air if its chuffing like f*ck after 3.5k. I know some td04's does do anything untill past 3.4k

Cheers for the input people, i'll get it up in the air tomorrow and have a gander! Got a feeling it's something to do with that naffing d-seal

[Ruan]

I doubt a D-Seal will cause enough air to be released for that....

You sure the pipe from turbo>intercooler hasn't popped off or split, that's a usual culprit.

[ADV_93]

I doubt a D-Seal will cause enough air to be released for that....

You sure the pipe from turbo>intercooler hasn't popped off or split, that's a usual culprit.

As said, i'll have a look tomorrow. I did get about 6-8 psi with mbc turned up

[toseland]

standard engine was 12-14, something deffo leaking..

[silverzx]

Ran my 1.9 205 on Lucas/TD04L for a good 8 months or so.

Span the wheels in the wet in 2nd/3rd.

Was pretty nippy, had no rev counter so can't comment on lag etc.

I had the older style Lucas if that makes any difference.

What was your fuelling/setup with it? If you can remember! I'm not certain on the differences between the pumps.

Can't remember, just gave it as much fueling as I could before RPM's started increasing at idle. Wastegate welded, 20~24 PSI depending on how it felt on the day.

[ADV_93]

Ran my 1.9 205 on Lucas/TD04L for a good 8 months or so.

Span the wheels in the wet in 2nd/3rd.

Was pretty nippy, had no rev counter so can't comment on lag etc.

I had the older style Lucas if that makes any difference.

What was your fuelling/setup with it? If you can remember! I'm not certain on the differences between the pumps.

Can't remember, just gave it as much fueling as I could before RPM's started increasing at idle. Wastegate welded, 20~24 PSI depending on how it felt on the day.

Running full max fuel atm, just a bit stumped as to the boost compensator set up. Hat is better? Wound all the way in, or out?



OK LADIES, after a day working on the pug, i found that my actuator arm to the wastegate lever was holding it off by less than a millimeter so the wastegate was basically always open. Took it off, tighted the arm and refitted. Refitted my standard inlet system with a reducer made by Derby Performance Hoses (who had it ready less than an hour later) which i can say are an absolute pleasure doing business with. Just my exhausts to sort now which is banging on my heatshield as a result of the exhaust downpipe flange coming off the turbo plate is causing my exhaust to sit about an inch further back. Wound the max fuel until stop and need to screw the compensator in just a little bit. Over all, she's kicking at about 10 psi but really takes off around 4,000 rpm, but then i hit the governor at 4,500 rpm

But yeah, thanks for the advice, i'll upload some pictures of her when i get some!

[306pc]

Time for a Bosch!
I have a spare?.....

[Ruan]

Still sounds suspiciously like you've got a chronic boost or exhaust gas leak.

Sure the actuator isn't stuffed?

Sounds like the spring has gone weak or snapped inside or simply you've not got enough preload so it's flapping about.

[ADV_93]

I'm suspecting the spring in the actuator has gone weak or something along those lines. Had it up on ramp, no signs of boost leaks, no blowing, no splits or tears in MBC piping and the MBC itself is brand new. Even the D-seal was all nice and rubbery still. If i can source an actuator, might be worth fitting it, not sure atm. MBC is brand new (fitting the ball and spring type soon, currently running a bleed).

First drive out in it last night, begins to spool around 2,500 rpm, but kicks really hard at about 3,000-3,500 rpm and carries all the way over consistently until it hits the governor at around 4,500 rpm. I don't tend to look at my boost gauge, but it hit around 10-12 psi, so not sure if my fuelling is limiting the boost in some way also. Kicks a lot harder than my old K14 did at 20-odd psi. Few pictures too.

[attachment=18395]
K14 and TD04. K14 had no play what so ever, still kicked i guess like the day it came from the factory.
[attachment=18396]
Ah yes, the turbo bolted up. Note the hole in the bulkhead was done via a BEAST of an air chisel.
[attachment=18397]
This gap was literally about the width of my finger.

[306pc]

Fuelling will be limiting the boost. The Lucas just can't deliver fuel like the Bosch can, certainly at high revs.

[silverzx]

Why have you smashed the bulk head up so much? TD04 should just fit in no modification required.

[ADV_93]

Fuelling will be limiting the boost. The Lucas just can't deliver fuel like the Bosch can, certainly at high revs.

It shows when you drive it. Definitely getting a Bosch ordered next.

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Why have you smashed the bulk head up so much? TD04 should just fit in no modification required.

Not smashed, air chiseled! No modification on a GT15 manifold, but on the T2 manifold it sat the turbo in a position where when i put the engine on it's mount it was hitting the bulkhead. I'd have loved to have not put a big hole in the bulkhead but it's the only way the turbo would fit

[silverzx]

Not smashed, air chiseled! No modification on a GT15 manifold, but on the T2 manifold it sat the turbo in a position where when i put the engine on it's mount it was hitting the bulkhead. I'd have loved to have not put a big hole in the bulkhead but it's the only way the turbo would fit

Fair enough, wouldn't lose sleep over it tbh.

[ADV_93]

Not smashed, air chiseled! No modification on a GT15 manifold, but on the T2 manifold it sat the turbo in a position where when i put the engine on it's mount it was hitting the bulkhead. I'd have loved to have not put a big hole in the bulkhead but it's the only way the turbo would fit

Fair enough, wouldn't lose sleep over it tbh.

Had to be done to get the turbo in!

[ADV_93]

Time for a Bosch!
I have a spare?.....

You don't still have that Bosch by any chance do you?

[306pc]

Pm'd.