123d Intercooler & Fuel Pump Upgrade!!!

[strixas]

Bought twin plunger pump what u do with long m6 bolt? Is no thread in new pump

[typergaz]

I personally drilled and tapped the cp4.2 pump to accept the bolt but others i know have just left it out

E82 123d 338bhp 485ftlbs Ecotune stage3 Now sold

[strixas]

I personally drilled and tapped the cp4.2 pump to accept the bolt but others i know have just left it out

E82 123d 338bhp 485ftlbs Ecotune stage3 Now sold

Thanks

[andrewuk1990]

I've got my car booked in to have the pump and rail fitted, manifold cleaned and swirl flaps removed at Darren Woods in Stockport next week.

Booked in for a remap at RS Tuning in Leeds by Paul start of May (kindly recommended to me by Jason at BWChiptune).

Stock my car put out 208bhp on their dyno this morning so all seems healthy. Hoping to hit 300bhp and 420+ lbft with the mods, already have the other bits needed.

Does anyone know what sort of boost is required on the big turbo for 300+bhp? Is it around 2.7bar? Was thinking this sounds quite high if it is!

[typergaz]

Mine made 298.9 @2.6 bar thats with stock hpfp just a external regulator to increase the hpfp internal pressure and to keep the pressure in the pump a bit longer before it dumps it back to tank. Best thing to do with these is the cp4.2 pump

E82 123d 338bhp 485ftlbs Ecotune stage3 Now sold

Now 2016 mk7 golf gtd.......

[typergaz]

My old 123d was boosting @ 2.9 bar for the 338 bhp anymore boost and it lost power even though the turbos can handle 3.2 bar they physically cant flow enough air volume at that pressure

E82 123d 338bhp 485ftlbs Ecotune stage3 Now sold

Now 2016 mk7 golf gtd.......

[Adie123d]

Fitted the CP4.2 pump on the weekend,
Here's a few pictures of the job.

I bought a 2016 model CP4.2 pump on Ebay woth only 6000 miles on it but has one outlet facing the opposite direction, This worked out very well though as there is nothing in the way on the rearward facing outlet plus it means you don't have to move the glow plug control unit out the way like you do with the model which has both outlets facing forward.

I also bought the two fuel lines that come with this pump, one is a direct fit and the other I bent so that it is routed under the inlet manifold and looks tidy.
I also bought two fuel rails the same as standard fit and had them cut and welded.

By using the same 4 cylinder rail all the standard rail to injector pipes are reused plus it sticks out far less from the front of the rocker cover than the 6 cylinder one.
I bought another EGR pipe too, so that I could have it capped and ready to 'beat up' when the operation commenced. The egr is electronically deleted but I had the intake end welded just incase it didn't seat properly in the head... but it did and now it doesn't protrude into the throttle passage either to cause any obstruction to the intake air.

All done, No leaks and the cover fits fine


Don't forget to get a pump removal tool.

[jgalea324]

Fitted the CP4.2 pump on the weekend,
Here's a few pictures of the job.

I bought a 2016 model CP4.2 pump on Ebay woth only 6000 miles on it but has one outlet facing the opposite direction, This worked out very well though as there is nothing in the way on the rearward facing outlet plus it means you don't have to move the glow plug control unit out the way like you do with the model which has both outlets facing forward.

I also bought the two fuel lines that come with this pump, one is a direct fit and the other I bent so that it is routed under the inlet manifold and looks tidy.
I also bought two fuel rails the same as standard fit and had them cut and welded.

By using the same 4 cylinder rail all the standard rail to injector pipes are reused plus it sticks out far less from the front of the rocker cover than the 6 cylinder one.
I bought another EGR pipe too, so that I could have it capped and ready to 'beat up' when the operation commenced. The egr is electronically deleted but I had the intake end welded just incase it didn't seat properly in the head... but it did and now it doesn't protrude into the throttle passage either to cause any obstruction to the intake air.

All done, No leaks and the cover fits fine


Don't forget to get a pump removal tool.

Super write-up! Many thanks for this who did your stage 3 remap? Or has it not been done yet?

[holendru]

Verry good write up...!!!
Got my parts laying around still no time for mounting.
Did you take the air out of the lines before starting the engine?
What are the results..???

[Adie123d]

It's booked in with Ecotune at the end of may to get remapped stage2+ for the new mods
So I'll post results when it's done.

And when it got it all kind of back together I just let it build up some fuel pressure with the ignition switched on, then cranked it for about 10 seconds and it started.
Was well happy as it was 1am in the morning and I was goosed.
It's running fine though So looks like I did an okay job with no leaks etc
Can't wait for the dyno time now

[typergaz]

It's booked in with Ecotune at the end of may to get remapped stage2+ for the new mods
So I'll post results when it's done.

And when it got it all kind of back together I just let it build up some fuel pressure with the ignition switched on, then cranked it for about 10 seconds and it started.
Was well happy as it was 1am in the morning and I was goosed.
It's running fine though So looks like I did an okay job with no leaks etc
Can't wait for the dyno time now

Have you checked your fuel pressure because all you need is going to ecotune and your fuel pressure is like this blue line is requested rail pressure and green is actual pressure.

Sent from my SM-G935F using Tapatalk

[andrewuk1990]

It's booked in with Ecotune at the end of may to get remapped stage2+ for the new mods
So I'll post results when it's done.

And when it got it all kind of back together I just let it build up some fuel pressure with the ignition switched on, then cranked it for about 10 seconds and it started.
Was well happy as it was 1am in the morning and I was goosed.
It's running fine though So looks like I did an okay job with no leaks etc
Can't wait for the dyno time now

Have you checked your fuel pressure because all you need is going to ecotune and your fuel pressure is like this blue line is requested rail pressure and green is actual pressure.

Sent from my SM-G935F using Tapatalk

Gaz please can you shed some light on why that graph is like that? I presume we would actually want the provided pressure to very closely match the requested, ie. Not like the graph!

Good write up and Pictures btw Adie! I have also just had mine fitted (by Mike123d at Darren Woods). He had the 6Cy rail cut, welded and fitted it for me complete with a set of fuel pipes bent as required. The pump I have has both nossles facing the same direction but this didn't seem to cause any problems on installation. He also blanked my EGR valve and I have had it mapped out electronically to boot.

https://goo.gl/photos/idywPK2E2fYCRL7EA

It runs perfectly just as it did before the mods, all I am waiting for now is what RS Tuning in Leeds can achieve on 9th May when it goes in for a custom remap.

[typergaz]

It's booked in with Ecotune at the end of may to get remapped stage2+ for the new mods
So I'll post results when it's done.

And when it got it all kind of back together I just let it build up some fuel pressure with the ignition switched on, then cranked it for about 10 seconds and it started.
Was well happy as it was 1am in the morning and I was goosed.
It's running fine though So looks like I did an okay job with no leaks etc
Can't wait for the dyno time now

Have you checked your fuel pressure because all you need is going to ecotune and your fuel pressure is like this blue line is requested rail pressure and green is actual pressure.

Sent from my SM-G935F using Tapatalk

Gaz please can you shed some light on why that graph is like that? I presume we would actually want the provided pressure to very closely match the requested, ie. Not like the graph!

Good write up and Pictures btw Adie! I have also just had mine fitted (by Mike123d at Darren Woods). He had the 6Cy rail cut, welded and fitted it for me complete with a set of fuel pipes bent as required. The pump I have has both nossles facing the same direction but this didn't seem to cause any problems on installation. He also blanked my EGR valve and I have had it mapped out electronically to boot.

https://goo.gl/photos/idywPK2E2fYCRL7EA

It runs perfectly just as it did before the mods, all I am waiting for now is what RS Tuning in Leeds can achieve on 9th May when it goes in for a custom remap.

The car will run perfectly with the fuel pressure all over the place if its only at stage 1 or stock!!, it would struggle to supply enough fuel like that if it was at stage2+ like i was at before the cp4.2 install. I for one nearly gave up on the 4.2 because it was worse at first than the modded 4.1 for fuel. If you do get fuel pressure fluctuations like that first thing to do is using DIS or similar perform a full fuel system bleed procedure. (This should be done before the initial start because turning the fuel pump without fuel in can cause premature internal wear because the diesel is the lubrication for the pump) Bleed procedure takes around 10-15 mins then you need to run a fuel pressure regulator adaption. Once they are done in that order the fuel system should be all good and hold 2000 bar solid

Sent from my SM-G935F using Tapatalk

[andrewuk1990]

Cheers Gaz. Appreciate the advice.

I ran a quick check this morning with Torque Pro graphing fuel rail pressure at WOT through 3rd and 4th gear. It seemed to build to 2k bar quickly and held it there perfectly stable so should be good to go fingers crossed.

[andrewuk1990]

My car went to RS Tuning in Leeds on Wednesday and achieved a genuine 290bhp & 435ftlb! This was on stock turbos and V-power diesel which I believe may reduce power slightly due to addition of cleaning additives etc. The turbos seemed to hit maximum air flow at a pressure of 2.4 bar, beyond which there was no advantage. No meth or water injection used to achieve the above so good for everyday workhorse use and track blasting which is exactly what I was after. The fuel pressure held nicely as requested by ECU so props to Mike123d for fitting the pump & rail for me as well.

Still having some trouble mapping out the EGR valve completely but Paul at RS hopes to have that sorted by next week. Other than that there's been no problems and it seems happy to pull with no clutch slip (yet)!

Have to mention Jason at BW Chiptune for referring me to Paul at RS Tuning in Leeds, I would happily recommend either tuner to anyone else looking for a good quality remap.

For anyone interested, the original Stage 2 map shown in red on the below graph was done by Elite Remaps in Leeds and it was a simple ECU remap on stock hardware. Their claimed BHP was 255-270... Not surprisingly it achieved less, 248bhp.