Technical Help needed Banjo bolt

[Dave Hoey]

Looking for help. Replacing intercooler pipes on camper (1997 fiat ducato 2.5) as it is down on power at high revs and noticed loose pipe below.

Think it's a vacuum pipe and has something to do with fuel system. I think I'm missing an banjo bolt. Any one point me in the direction of what I need to reattach pipe?

 

[bugsymike]

I think from memory it is a hollow bolt with a copper washer either side to provide a vacuum control to the diaphragm on Bosch injector pumps when fitted with turbos.
If you root around a scrapyard you may find similar on an old Bosch pump from a different make vehicle, I think it is a fine thread and easily broken.
A diesel pump reconditioners should have one in stock.
At one time I was told to remove the sealing blank in the centre of that housing to adjust boost performance.
However when I put the Ducato 2.8 TDI engine in my boat the best performance increases were by adjusting the fuel at the threaded shaft and locknut in the centre of where the four injector pipes come out of the pump, this caused black smoke and so you then adjusted the turbo boost at the waste gate to increase the oxygen which got rid of the black smoke and so on.
By doing this I got near to the performance of the original 150Hp V6 petrol engine.
If really stuck getting the correct bolt , if you find one of the same thread and length you could drill it in the correct two places and with copper washers either side it would work.

 

[Communicator]

I agree with @bugsymike 's suggestion that a banjo bolt and two copper washers are missing. The obvious place where the pipe should be connected seems to be on the boost pressure housing of a early Bosch VE series or similar pump. I am not an expert on Bosch pumpd but see this link. There seems to be some similarity. Perhaps Diesel Injection Pumps could help? (www.injectionpumps.co.uk)

I suggest trying to read the pump details, as this would probably help in identifying the correct part. If I am correct the the missing connection could explain the lack of power. However I am curious to know whether it is a vacuum or turbo pressure connection?

 

[bugsymike]

I suggest trying to read the pump details, as this would probably help in identifying the correct part. If I am correct the the missing connection could explain the lack of power. However I am curious to know whether it is a vacuum or turbo pressure connection?

Not certain, but suspect it is vacuum as above the diaphragm in that roughly rectangular housing, but equally so if pressure it could push against a spring and the diaphragm. So hedging my bets.

 

[Communicator]

Not certain, but suspect it is vacuum as above the diaphragm in that roughly rectangular housing, but equally so if pressure it could push against a spring and the diaphragm. So hedging my bets.

I was looking at the cross section on the boost housing in this link. The diaphragm D, sits above (connection side) of spring E, and is presumably shown in the initial position against adjusting screw C. In the diagram, the diaphragm can only move downwards with increased pressure at the inlet port at upper right which is where I assume the loose pipe should be connected. However, I remain open to alternative interpretation.

 

[bugsymike]

I was looking at the cross section on the boost housing in this link. The diaphragm D, sits above (connection side) of spring E, and is presumably shown in the initial position against adjusting screw C. In the diagram, the diaphragm can only move downwards with increased pressure at the inlet port at upper right which is where I assume the loose pipe should be connected. However, I remain open to alternative interpretation.

I suppose the answer is when running to stick finger over pipe.

 

[Communicator]

I suppose the answer is when running to stick finger over pipe.

Being a banjo fitting, it would have to be finger and thumb.

 

[Dave Hoey]

Thanks for all the helpful responses. My power loss at high revs is definitely down to this I believe. Hard to imagine how bolt worked free.

I have trawled the net but have no idea of the right type banjo bolt. I don't want to get the wrong one as it will destroy treads in pump.

It's the bolt circled on red in the photo I believe I need if anyone can point me in the right direction?

 

[jackwhoo]

You could try land rover part number

err886

Google it.

If you do only attempt to screw the bolt in with fingers (no pipe or washers attached) to make sure thread is correct size and pitch.

 

[jackwhoo]

From the photo The pump looks like could be a Bosch ve, land rover used the Bosch ve on its 200 and 300 two engines years ago now but land rover parts are easy to identify and find .
Vw 1.9tdi also used bosch ve.
Peugeot and Citroen too on their 1.9 td

Do look further at your pump to make sure .

 

[Communicator]

As I suggested in post #3, perhaps "Diesel Injection Pumps", to whom I linked, may be able to advise or supply. A starting point would be any info that can be gleaned from the pump label, supplied with that they may be able to supply or direct you to a supplier.

 

[Communicator]

Thanks for all the helpful responses. My power loss at high revs is definitely down to this I believe. Hard to imagine how bolt worked free.

I have trawled the net but have no idea of the right type banjo bolt. I don't want to get the wrong one as it will destroy treads in pump.

It's the bolt circled on red in the photo I believe I need if anyone can point me in the right direction?

@Dave Hoey , unfortunately you have not included any indication of scale in your original photos. At a guess somthing like M10 x 1.0mm would be in the right area. This is a standard brake bleed nipple thread size. A local accessory shop, or garage should be able to supply a sample to use as a thread gauge. For reference a 9.5mm drill is a loose fit into an M10 female fitting, when used as a plug gauge. M10 banjo bolts are available on Ebay if this size is correct, but you would have to veify unthreaded length.