A bit of an update on the update on the Peugeot Expert DW8 with Lucas pump
The new seal in the Lucas pump only lasted a few hundred miles and the van got parked up and forgotten for a while.
Then my son decided he'd like a veg van and based on the rarity of the Bosch equipped DW8 and internet info including a few people claiming it was a pretty straight forward swap, he was up for converting this one borrowing bits from an XUD Turbo Xantia engine that he had for another project.
This turned out to be a far from straight forward swap so if anyone else is considering this, read this for some of the pitfalls he came across.
First he removed the Lucas pump and bracket to fit the XUD pump and bracket but the XUD mounting bracket doesn't fit the DW8 block as the mounting holes are in different places.
He then drilled and tapped the DW8 bracket to accept the XUD Bosch pump and fitted it to the van but soon realised that the pump pulley was too close to the bracket.
After a bit of head scratching we ended up using the Bosch pulley mounted to the Lucas pulley hub. The bolt on bit (left hand thread) of the hub nearest the bracket interfered with the bracket so was unbolted and binned.
This now threw the pulley 10mm too far out but he machined a custom spacer to go between pump and bracket and got it to all line up great.
The keyways were different thicknesses so he had to machine a custom woodruff key to marry the Lucas and Bosch keyways.
The general internet consensus was that you could fit Bosch XUD injector pipes bent slightly as the DW8 injectors are at a slightly different angle so he did.
Lucas injectors pop at a very similar pressure to n/a Bosch injectors so they could stay.
He fired it up and it ran well but a bit advanced so he timed it up with a dial gauge and it was running and revving sweet.
Time to breathe a sigh of relief and put it back together.
A new cambelt kit was fitted, covers and engine mounting put back on and one of the last jobs was to refit the plastic inlet, what could possibly go wrong now?
Well .... the inlet wouldn't go back on, the XUD injection pipes were preventing it from locating at the rear plus the extra height of the turbo pump meant the front didn't fit either.
He'd done so much work to get this far that he was committed, but sensibly the only way this was going to work was to use DW8 Bosch injector pipes and a n/a pump.
I called a friend who is into 306s and he said he had a running 1999 car with n/a Bosch pump that he would break so off we went.
Turns out it is a DW8 with Bosch pump and all the above could have been avoided by fitting the bits from this 306 so that is the new plan.
So, fitting an XUD pump to a DW8 is clearly possible but not as simple as the armchair internet experts would have you think!
I’ll update again when the old girl is finally up and running proper.
