manuel pump for 1kz

[ToyRover]

need a manuel pump swap it sounds like the go is a 4m40 pump but i cant find any detailed info on the swap anyone got one thats been moded in auckland that i can look at or talk to cheers karl
021 2399 650

[kbushnz]

I am doing one at the moment....But using a 2LT and 1KZTE pump hybrid...
There is a shop in Chch which does them.....
Calvin

[KIWI_TERRANO]

ring diesel services in chch about 4m40, there starting to do them now, i wil be doing it on my truck when I turbo it.

Its a bolt on set up that may require custom fuel lines and throttle linkages.
do some google search cause its ment to be popular in oz

[ToyRover]

i got a price think its a 2lt 1kz hybrid with a different head its 1700 quite a bit but there no other way round it

[KIWI_TERRANO]

dsl are saying 600-1000 fitted and tested for 4m40, and its got more flow through the nozzles than a 2lt hybird, the 4m40s have a factory 12mm plunger rather the 2lt have 8 or 10mm cant remeber but most people #### round and fit 12s into them but they still dont have a good flow like 4m40s

[kbushnz]

The hybrid 2LT pump I am getting is only $1000.. If I supply the donor pumps.
Talking to the guy they swap the internals around and do some mods. (secret stuff he wont elaborate)
Put on a new 12mm size head. Bench test it and dial it in...
Boost levels required 18psi min...
They can set it for what style of driving you want...or what boost you are running.
They have a test truck and the hybrid pump has evolved over the last few years..And they have been doing it for awhile now..
Decided on this path as I can use 2LT linkages and connections... All the fuel lines will reach...So easer install. (we will see )
Sending the pumps off later this week...
Calvin

[KIWI_TERRANO]

Dsl prices incl pump and fitted, if your sending yours to kiapoi repowers they do I described ,as I have been looking hard into it to see what the best option in the long run (eg if pump shits out in middle of no where) the parts are easily avaible instead of having to strip it and resend to people who did work.
Im not getting up you but its just hat Ive found.

[kbushnz]

Yeah I hear what you are saying....
If I lived in Chch DSL may have been a good option....
But I am up the other end of the country....
What ever we do its got to be better than the EFI pump....
Look forward to seeing how yours goes in future....

Calvin

[KIWI_TERRANO]

Look forward to seeing how yours goes in future....

Calvin

Hopefully fast hahaha

[ToyRover]

so who in auckland do them?

[kbushnz]

Well the new hybrid Injector pump arrived today.
Looks the part....
Have the linkages so will look to install it over the Xmas break...

[kbushnz]

Well Started yesterday and made room for the pump removal.
Battery boxes out and inner guard.

Today I removed the old pump. Had to make up some tooling to press out the taper / keyed shaft.
Prick getting to the back bolt for the pump....Gunna have trouble getting to it while I set its timing.
Plenty of room when its gone...

Below is a pic old v's new.
Before the new one went it I added some connectors to the Tacho sensor and fuel cut valve.

Fitted up no problem...Even all the hoses reached.
The spill hose from the injectors was shortened a bit and I had to adjust the tube from the pump to reach / align with the hose.
All the injector pipes fitted as before.

Once I had it mostly together, well enough to run ... Primed pump....
Put on battery and after about 10 turns she fired into life....Phew it works.
Next step it to tidy up wiring and install throttle cables..(Going to need to do some fabrication for this bit.
But done enough for today.
However I think I will have a box to drop next year , trans oil leak coming from bell housing....Changed that seal when I did the head some 6 years ago....
So looks like its coming out again. Should have enough room to move box back as opposed to last time when I pulled out the motor.

[DDAN]

Well done on the install, the Mechanical pumps really wake these engines up, Ive done over 60,000 kms on my pump no problems, in fact ive been getting better fuel economy, now time to turn the boost up

[kbushnz]

now time to turn the boost up

What boost are you running now?? The guys who did my pump say its set up for min 18psi....
Once I get the throttle linkages sorted I can then dial it in and set the timing and boost....Can't wait...
Need to extent the arm down on the 2LT linkages...Job for next week or after Xmas....
Does your Tacho work off the manual pump sensor?? or did you need to get it calibrated...

Cheers
Calvin

[DDAN]

Hey Ive been running 20 pound of boost at the inlet mainfold, so porb 22 at the turbo, but I have a preturbo nozzle set up to spray over ten pound to keep the turbo cool, as before that it would go up to 130c at the turbo, now it is cold to the touch, my rev counter still works but is way out, so I just drive to the EGT

[kbushnz]

Well as I am on late shift this week, I have had the opportunity for a play.
Have fabricated the throttle quadrant. (needs a tidy up, gee I love having a welder )
Had to modify the 2LT unit..
Add 50mm so the arm is lower and inline with pump.
Add 35mm to the clip on rod length so it gets full movement.
Then graft it onto my intake manifold using the locations for the factory manual pump (European models).
Now its time to change over the throttle cable and put on the adjusting mount.
After that a feedback cable to my TPS and transmission lift cable.

Also make the coolant hose that was used on the original throttle body shorter.... Gets in the way of the rod.
Purple arrows show the attach points used and also had to adapt one of the stays for my intercooler install as it used that factory quadrant mount.

Hopefully get a bit more time on it tomorrow

[kbushnz]

Quick question for those 2LT, 3L owners..
Does the fuel cut solenoid operate via a relay or direct.
Cant find a wiring diagram on the net....

Cheers

[slide]

Direct from ignition, through a fuse, I think fuse that also controls gauges.

[slide]

I have a preturbo nozzle set up to spray over ten pound to keep the turbo cool, as before that it would go up to 130c at the turbo, now it is cold to the touch, my rev counter still works but is way out, so I just drive to the EGT

130c at turbo? Do you mean the compressor outlet temp?
Do you have an intercooler as well as nozzle spray?
and did the nozzle sprayer reduce EGTs much?
cheers, Nath

[DDAN]

130c at turbo? Do you mean the compressor outlet temp?
Do you have an intercooler as well as nozzle spray?
and did the nozzle sprayer reduce EGTs much?
cheers, Nath[/quote]
Yes that's right, now the turbo is cold to the touch even at long periods of high boost, yes I have a front mount intercooler, at 100 km with the spray on it will drop over a 150c of, and the right foot flat she wont go over 550c before she would just keep climbing

[kbushnz]

Direct from ignition, through a fuse,

Thanks for that....
I found a spare round plug in the wiring loom between the battery and inner guard. (take note those who are going to do this)
Has one big fat white wire (Batt + all the time) and one red wire (Batt + when key on run....not acc) So this red wire will power the fuel cut off solenoid. Will track its fuse back later....
Not sure what it was meant to drive.....But the white batt power all the time could come in handy to tap into...

Did a bit more in the last few days... Fixed a leak in fire wall, only been there 10 years but while it was in bits..........No more puddles on the floor when it rains.
Also reduced the length of the hose between the head and block.

Just cut down the original one....and used its existing bends to my advantage.
Now to clean up all the coolant on the garage floor

Guard is now back on and one battery tray installed, battery on charge.....
Bit flat with all the cranking and only running for a few mins...

Thats it for today, will play with the throttle next week......

[kbushnz]

I found a spare round plug in the wiring loom between the battery and inner guard. (take note those who are going to do this)
Has one big fat white wire (Batt + all the time) and one red wire (Batt + when key on run....not acc) So this red wire will power the fuel cut off solenoid. Will track its fuse back later....

UPDATE !!!!! There is not enough current in the Red wire to activate the solenoid. So I tried to have it throw a relay...... Still wouldn't activate a flippin relay...It has Batt voltage....Grrrrrrr Need to find another power supply. (note relay and fuel cut works fine from Batt)

[kbushnz]

Sorted power to Fuel cut.....picked up a wire from in cab via a hidden switch....
Slow down any Thievery...

Throttle all done now, got a Nissan Maxima throttle quadrant....(monstr will appreciate this )
Welded to 2LT unit....At the appropriate distance from center to give me the pull to have both throttle on pump and TPS unit move from stop to stop.


Taken her for its first blat around the block....and dial in the boost...
Wow what a difference....
Fires up first pop and strong....
Auto appears to shift just fine.....
And when you give her a kick in the pants it pulls........
Just a hint of black smoke....

Pedal a bit heavy with all the springs and cables (drag) will tweak springs to get a softer pedal....

So far so good......
At least its mobile again.

[DDAN]

Good stuff now you will be able to make full use of your intercooler

[kbushnz]

Reduced the spring load on the loud pedal, but will change it all around later....
Adjusted the timing a bit today, bit rattly when hot...
Man it pulls.... Just cruising around the burbs and one hill which used to cause the EGT temps to climb high with a bit of gas and it was a bit gutless.... now just pulls away and temps are alot lower....
Will do some motorway runs next week......

Very happy camper !!!

[Ginzu8]

Hey Calvin. How much did the whole exercise cost in parts etc??

[kbushnz]

Well that's a good question....Now this has been drip fed....If the missus new the total cost I would be in.....well you know
The pump and donors cost close to $1300 -1400.....Buying pumps on the cheap...
The guys who did my pump can supply with just using your old pump but the cost is higher...And you don't have a truck...
The fabrication work for throttle linkages was my time...But it took me a few hours of trial and error to get it just right.
Then about $200 for odd bits like throttle linkages and cables.....
Still to go is sorting out the Tacho and Auto.....

I can recoup some costs and sell off my old pump....
As it was working fine before removal.

[Ginzu8]

Sweet thx Calvin. Spoke to my diesel mechanic today about my injectors. Right now I don't notice black smoke when I drive but it's hard to see from the drivers seat. But I am only doing 480kms per tank but the mechanics recons the use of air con is the main reason for my poor economy. Now I am wondering If I should do my injectors n he recons that u shouldn't just get another set of injectors as it has to match the pump. Is he full of crap?

[kbushnz]

Now I am wondering If I should do my injectors n he recons that u shouldn't just get another set of injectors as it has to match the pump. Is he full of crap?

Hmmm... Sure they need to match the pump / engine type to a point (Type of nozzle).....But a good diesel place like Simms should be able to do it...(I am sure there are others)
If the mechanic has the right gear and manuals then its easy, sounds like he doesn't have the gear or knowledge.
The injectors are set to pop off at a certain pressure and also have the right spray pattern, .....They all also need to be set the same....

Sometimes they just need a clean and check. Other times like my old set needed new nozzle tips and reset again (use little shims inside to set the pressure they pop off at)
I used to set nozzles similar to the diesel ones when I was an apprentice, these were for jet engines but did the same thing....
And as it happens a mate at work over Xmas cleaned checked and adjusted a set of nozzles for his Chevy truck... (quiet night at work)

[kbushnz]

YAAAAAHOOOOO
I have finally got my tacho working......
Monstr will appreciate this as every time he came by I was in the truck with spaghetti wires out the dash.
After much research and getting quotes (some upward of $200+)
I purchased a kit from Jaycar....(Suggestion from an auto electrician)
Assembled it and put it in truck, followed instructions but couldn't get the thing to work, got the occasional flicker.
Grrrrrrrr.
Re read instructions and followed to the letter. Still no go.
Then tried to use another signal....still no luck....
Reread instructions, checked soldering...All fine.
(this over two days on and off tinkering)
Then only 20 mins ago looking at the picture in the booklet...(Monstr had just left)
Ding.... I needed to add another jumper pin in....
Put pin in, followed instructions and hey presto....Signal to Tacho.
Adjusted pots and got it to show idle speed.
Sweet.
Set it at fast idle, used hand held rev counter (laser) got rpm's and checked Tacho in truck... Adjusted pots to match...
All done....
Now I need a beer ! and have a swim.....
Tidy wiring up tomorrow...
Very Happy Camper.