Ford Mondeo 1.8 TD: Lucas/Delphi DPC8444B800A injection pump: info

[mtanner]

Hello!
I'm looking for information (workshop manual, exploded views, funtional description, partlists, testplan,...) for the Lucas (Delphi) DPC8444B800A diesel injection pump built in my mondeo 1.8 TD MK1 1996 to fix the problems I have with it.

If you have access to the above information or to the delphi direct evolution system I would appreciate If you could send/upload the files.

Many thanks in advance
CU

[mattmatt]

What is the problem you're having? May have the info but depends exaxtly what you need

[mtanner]

Hello,

thanks for your reply.

What happend?
The bottom part of the plunger of the electric diesel shutoff solenoid on the pump broke in small parts and these entered the pump.

As the diesel pump now leaks somewhere between the low and high pressure part of the pump (maybe this is not related to the above) and has now "bad"/slow/delayed throttle response I need to disassemble, clean and reassemble it with new gaskets, o-rings and ....

Therefore I'm looking for information regarding the operation of the pump and all the timing- and fuel-control elements in and on the pump to make myself more familiar with the pump before I start to disassemble the pump.

Any help wellcome.

Many thanks in advance
CU

[jonniebravo]

I have uploaded Service Manual for DPC pump exported from Delphi Direct Evolution, I don't have test plans but there's more tech info about that pump that i'm going to upload tomorrow.

Download 000005UA 001 pdf for free at Uploading.com (http://uploading.com/files/AMFEAH6W/000005UA.001.pdf.html)

[mtanner]

Hello jonniebravo (http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/),

Thank you so much for your upload. The download worked and I'm beginning to study the manual.

I appreciated your help very much.

Thank you!
CU

[ashok3377]

Hi,
Thank you so much for your upload.'ll u please upload it again in Rapidshare ? Thanks in advance!!!

[jonniebravo]

It's not so good idea to upload on Rapidshare because I dont have Premium Account, which means only ten of you guys could download this pdf and after that someone would have to upload again. Someone with collector account could download this file and upload to Rapidshare.

[smirnoff_rules]

It's not so good idea to upload on Rapidshare because I dont have Premium Account, which means only ten of you guys could download this pdf and after that someone would have to upload again. Someone with collector account could download this file and upload to Rapidshare.

upload here m8 in a rar or zip file , upto 30 mb . the paper clip in attachments

[ashok3377]

i have Rapid share premium account dude.pls upload it 1ce.so tht i can upload it again from my RS account for other members!!!

[jonniebravo]

Uploaded here:

[jonniebravo]

Here's more stuff, if you need more documents tell me I will look down in evolution software.

[mtanner]

Hello jonniebravo (http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/),

many thanks for your second upload regarding the DPC pumps.

For all who have already downloaded the first manual (000005UA (http://www.digital-kaos.co.uk/forums/attachments/f68/3697d1245176998-ford-mondeo-1-8-td-lucas-delphi-dpc8444b800a-injection-pump-info-000005ua.001.rar)), the exploded views are on the last pages in the manual too.

jonniebravo (http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/), if it is possible to get the part lists that correspond to the numbers in the exploded views that whould be great. I'm wondering if there is a "functional description" of the DPC-pump available as well, which describes the operation of the various part in and on the pump?

From the delphi-www-site I got the info that there are testplans as well available in the delphi-software-package although not in the "lite" one. In another thread I saw that you are looking for a testplan as well. If you got one, I'm interested in that as well because the manual (000005UA) refers to the testplan for the actual values to use over and over again.

Many thanks in adavance, for that jonniebravo (http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/)!

CU

[armpower]

Here's more stuff, if you need more documents tell me I will look down in evolution software.

Hallo Jonnybravo

Have you got some sort of manual ,technical info or technical solution for Delphi Epic pump.
This pump is installed in Fiat Punto 188 1.9d and Doblo', some variants also on Peugeot and Renault.

Thank you in advance, have a nice day.

[jonniebravo]

I have forgotten for part list........ :stupid:
@armpower do you have part number for that EPIC pump because there's I and II generation and also III, also there's direct injection pump....

[armpower]

For jonnybravo
The pump number is 8640A121A.
Thank you in advance for your help.

[jonniebravo]

Just a quick one
@mtanner there's principle of operation for dpc pump and it has 56 pages, but I'm having problem with extraction with PdfFactory (don't know why) I will try again tonight or tomorrow morning. No test plans, sorry just don't have them.
@armpower there's workshop manual, principle of operation and all other stuff for that one, I will upload tonight or tomorrow morning.

[jonniebravo]

I have exported all documents you've asked for, but I'm having problems with internet at the moment so in the morning I will upload all of them.

[mtanner]

Hello jonniebravo,

thanks for working on the documents again. Awaiting your upload.

Many thanks in advance!
CU
(http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/)

[jonniebravo]

Here they are:

[montreal]

Good evening Jonniebravo,

I'm wondering, do you also have the manual regarding the lucas/Delphi EPIC pump part no. R8640A111B ? Or is it the same as the one posted earlier?
all help will be much appreciated.

The pump is of suzuki samurai 1.9 D renault engine

all the best

S?rgio

[jonniebravo]

@montreal I'll give you answer tomorrow and documents if it's different.

@jonniebravo Thanks mate.

@Jonniebravo is it the same?

best regards

mate, there's no pump with that part number inside delphi direct evo. R8640A100B is closest part number to yours and if yours is the same and probably is you could try with those files, all those pumps are similar.

@mtanner I have found only these two there's no service instruction 66 and that last one(I couldn't find).

[robertmnorton]

hi,just a quick question as to why the EPIC has such bad press? is it design or just poor fuels/maintenence?

[smokeme]

hi,just a quick question as to why the EPIC has such bad press? is it design or just poor fuels/maintenence?

From what i've learned on my research the pump is actually reliable..

it's sensitive to static timing, the static timing has to be spot on as the pump ECU will only compensate a few degrees (i think it was 4*) if it's off more then that it gives error codes mostly relating to rotor position sensors.. most people take that as a faulty pump without actually checking the basics..

I know of some cars with over 300k on a stock pump including one Pug 406 with almost 450k without ever giving problems, my own car has 130k and so far so good..

From what i read some people say it doesn't like SVO like most lucas pumps.. There is also a saying the pump will overheat when used for prolonged times of engine braking since no fuel will circulate through the pump on everrun..

maybe someone here will know better..

[cri1410sti]

i have something like that on my sierra 18td. lucas-cav rotodiesel.
what are the full specs of that pump?

[Davmazi]

Very thanks for schema and files to lucas pomps, I have a big problem with immobilisser in this pump. You know something how he works in this pump?

[mr-tbo]

Is the pump same in Escort TD 1998?

[ttomek]

Jonniebravo

I have clio 1.9d f8q632 engine, same engine was put in Kangoo and Volvo models. There is a Lucas Epic pump. Can you send me technical documentation about this pump when i provide you pump number?

Thanks,
Tom

[monfan47]

Hello, is it possible to renew the throttle seal without dismantling, on a endura 1.8 diesel engine,

Thank you

[wer4]

mine is leaking out of the soleinoid above the turbo actuator around the wires

[jpv2003]

I am looking for schematic diagrams of Lucas injection pump for Ford Mondeo 1.8 TD of 1995-1996.

Thanks for reply.

[swartalf]

Hello, is it possible to renew the throttle seal without dismantling, on a endura 1.8 diesel engine,

Thank you


Nope, you have to dismantle the pump cover because of the throttle lever parts which are at the inside of the pump and under the cover. Dismantling itself is quite easy and you can find the two seals for the throttle axis in almost any hardware store. Just make sure they are the same size and are diesel-proof!

[clcasal]

I need the files attached in this post, the dpc files

thanks

[rangerx]

I need the files attached to this topic, too.
Thanks.

[meiki]

Hi jonniebravo,
Many thanks for making the EPIC-info avaible. I'm a newbie in this forum coming from germany and could not get such technical information in my country.
I hope that this will help me solving the problems with my '96 Xantia 2.1TD (135k) which has got leaking EPIC, a non working stop solenoid and recently develops some trouble with instable idle, i.e. during warm up the engine rev goes up and down (sawtooth up to 3500).
BR
Meiki

[drover1]

hi, would it be possible to send links for the dpc files please
cheers

[bobjones]

Thanks for the info - been searching high and low for it. Hopefully this will answer many questions and let me play with a spare pump with a bit more understanding than before!

Edit - I'm having problems downloading any of the files attached in signatures. It's not returning the forum error message of you haven't posted enough messages, just not doing anything! Opening in a new tab brings up a blank white screen. Right click -> save taget as doesn't work either. Any tips please?

[davidcie]

jonniebravo, you're a star! I've been googling for DPC pump info, manuals... just about anything concrete actually, and after hours of going through useless forum pages in Polish I came across this thread - and bingo!

It's thanks to people like you that the rest of us are able to learn intimate and fascinating details of how our vehicles operate.

Thanks again!

Edit: Um, having the exact same problem as the fellows above: unable to download files! Could you please look into it?

[ricsold]

Hello people!
I am fighting with troubles on my Renault Kangoo. It is equipped with a Delphi H111.027 Diesel Pump. Renault service told me that this model of pump can not be repaired.
I am looking for technical information (technical manuals, schematics, etc) in order to find a solution. Any help will be appreciated!!!

[barisd]

I want to ask if you know the equipment required to test these pumps

[ttomek]

for renault issues with R8640A111B pump...look at dialogys note NT 4737A, which describes how to fix that crappy pump, it worked for me...

[rxhughes]

I've had a recent problem with my Nov. 1999 1.8TCI Endura DE. Basically it would crank over for a long time before catching and even then it would be lumpy. I stuck a couple of lengths of clear fuel line on the supply return and noticed that if i had not started the engine for a while the symptoms appeared - long story short, under the pump is a large bung with what appeared to be a wet patch of diesel - i unscrewed this plug and replaced the 'O' ring - wet patch disappeared and no more air in the fuel line - I guess the seals on the top of the pump will start to go soon :-)

[Digital Auto's]

Anyone sorted this blank screen problem when hitting links????

[rxhughes]

Hi guys, just wondering if anyone out there has the exploded diagrams for the Lucas / CAV DPCN (DPCF) pump fitted to the Mondeo Mk2 (1999 MY) 1.8 TCI engine? Thanks to all who replied to my PM's, but so far the original PDF's appear to have been lost in the ether. My own pump is leaking now pretty much at every orfice (veggy oil abuse) and I'd rather not drink a diesel flavoured cuppa if I can help it ( we live out the sticks and we have our own well for water :-) Hope someone out there can help and thanks again to all who replied.

regards
rxhughes

[Car Killer]

I need info about these manuals,i have Ford escort 1,8 TD and need info about Diesel pump assembly made by lucas.

[muki]

hi guys having same problem, too, lets see if i can get some files so will keep me going with this :)

[muki]

hi guys , a have a pain call kangoo 1.9 diesel f8q632 engine and likes to keep me busy all the time, the lucas pump is after my mental health now is a r8640a111b. i have lots of white smoke coming out of the exhoust and rough idle every now and then. i done the head gasket not long ago so cannot be that, is Lucas i know. also there is lots of air in the diesel pipes one mechanic says is normal and that the car remove it by itself but not so sure, no leaks anywere. can anyone guide me a bit please? thanks in advance

[muki]

[QUOTE=ttomek;448729]for renault issues with R8640A111B pump...look at dialogys note NT 4737A, which describes how to fix that crappy pump, it worked for me...[/QUOTe
sorry ttomek but is dialogys a name from someone i am new here cant find it, thanks

[willeo]

Hi,

I have Escort 1.8 TD w intercooler. When in idle, it is smoking a lot and won't pass next MOT. I read from an ancient newsgroup thread (in Finnish...) that excessive smoke may be resulting from an electric problem, +12V missing on some of the wires to the Lucas pump. Something to do with injection advance, perhaps?

Does this ring any bells? Haynes manual does not contain any helpful information.

[vasilen2003]

Hello! my problem is a 1997 Ford Mondeo 1.8 TD injector pump I replaced with another from scrap yard and the engine does not start when key is in contact Red Light next to clock flashig fast.any help please?

[vasilen2003]

Hello! my problem is a 1997 Ford Mondeo 1.8 TD injector pump I replaced with another from scrap yard and the engine does not start when key is in contact Red Light next to clock flashig fast.any help please?
email me on ( no addys :rulez: )

[willeo]

Hello! my problem is a 1997 Ford Mondeo 1.8 TD injector pump I replaced with another from scrap yard and the engine does not start when key is in contact Red Light next to clock flashig fast.any help please?
email me on

The electric part of the pump has remained a mystery for me (have not found any electric schematics yet), but to my knowledge there is an im*obilizer, which is paired with your key. Perhaps you should take the electronics from the old pump. (Hope you get this reply.)

Anyone, where could I find the schematics, or a comprehensive explanation how the electric part of the pump works? Probably would help Vasilen, too.

[dafdiagnos]

Hello! my problem is a 1997 Ford Mondeo 1.8 TD injector pump I replaced with another from scrap yard and the engine does not start when key is in contact Red Light next to clock flashig fast.any help please?
email me on
it's definately an immo recognition fault m8. if you can't reprogram to match you can remove the armoured plate from back of pump & put ign feed to solenoid to start vehicle

[radistoev]

Someone said, the Lukas does not like the SVO fuel. What would be the influence if I put this kind of fuel?
Breaking the pump because too thick liquids, or just poor performance of the car?
What about preheating the SVO up to 80, 90 degrees? I am goint to try preheated SVO, with some 10% diesel mixed.

[radistoev]

Ok, kind of fake? Be happy, bye

[dafdiagnos]

if you mean biodiesel, my preference is to avoid like the plague- causes too many problems. it will block the rotors in the pump & cause alot of waxing issue. if used mix with at least 50% proper diesel to thin it down.

[bluen0se9]

Does anyone know of any reliable sites or places to order parts from for these pumps?

[tomash]

Hello to all,

I'm new here, and I have also problems with lucas epic pump. Do you have any material about lucas epic in Fiat ullyse?
Thank's!

[Benido]

Hai, actually I had exactly the same problem last week with my Mondeo. I replaced it for an Delphi pump from the Scrap yard. The only option was to built out the pump again since the immobiliser on the replacement pump can only be programmed once when it is new.
I took both pumps to the diesel specialist where they build in a new solenoid wich just operate on 12 volt (the one they removed was one with an intergraded immobiliser. I also ask them to remove the imobeliserbox from the old pump. Underneat a removable cover from this box there are two connections from wich you can use one to activate the solenoid. Fasten this box somwere else in the enging compartment and it will recognize your key to.

Maybe you already have beaten theis problem, but just in case..

Regards,

Benido

[craigiepie]

Ford Mondeo 1.8 TD: Lucas/Delphi DPC8444B800A injection pump: info

[JoeN!]

My DAF 400 engine won't start... no diesel and the problem is after the filter...
Can anyone help

[dimitar22]

My DAF 400 engine won't start... no diesel and the problem is after the filter...
Can anyone help

Be more precise how the problem occured, with the info you gave i can't help you.

[sonce_moe]

After having big problems with the lucas pump in my mondeo '94, stumbled upon this site and was very surprised to see what else it has :). Thank you and keep up!

[zeropop]

I have a problem with my injection pump on my Ford Sierra 1.8 td, oil filter iz full of diesel injection pump is full of diesel but nothing is coming out of injectors ! Whe have tried the stop valve it`s good, manual pump is ok and free of air, regulator is ok, but on the output pipe of injector there is no fuel. The injector made is Lucas.:banghead:

[BimmerGT1]

Here's more stuff, if you need more documents tell me I will look down in evolution software.



I do thank you for this info but i cant download this files, could somebody uploaded to rapidshare or another site please

[zarn]

Hallo Jonnybravo

Have you got some sort of manual ,technical info or technical solution for Delphi Epic pump.
This pump is installed in Fiat Punto 188 1.9d and Doblo', some variants also on Peugeot and Renault.

Thank you in advance, have a nice day.

Same problem here. My Kangoo pump is dead. Docs will be much appreciated!:congrats:

[Deutsch1978]

Will this info apply to all pumps dpc????

[almnam]

hi dear
need Calibration test sheet for
0 445 120 304 Bosch
EJBR03301D Delphi
thanks in advance

[jonniebravo]

GUYS, I'VE ALREADY UPLOADED TWICE ALL THE FILES, ASK MODERATORS WHY DID THEY REMOVE THEM.

[gmb45]

jesus talk about dragging up the past, this thread is 2 years 8 months old, the files where lost a long time ago when we moved server.

[Meat-Head]

GUYS, I'VE ALREADY UPLOADED TWICE ALL THE FILES, ASK MODERATORS WHY DID THEY REMOVE THEM.

jonniebravo (http://www.digital-kaos.co.uk/forums/members/47652-jonniebravo/) Member

Join Date: Apr 2009
Posts: 91
Thanks: 68
Thanked 77 Times in 35 Posts
Downloads: 2
Uploads: 0


Perhaps if you was on here more often, you would know that DF decided it was cheaper to remove PERMANTLY the automotive software section, rather than concrete over his rose garden that kept getting trampled on by lawers.


jesus talk about dragging up the past, this thread is 2 years 8 months old, the files where lost a long time ago when we moved server.

Yeah, maybee so, but at least there no Stella stains on this thread, it's in perfect condition.

[jonniebravo]

Perhaps if you was on here more often, you would know that DF decided it was cheaper to remove PERMANTLY the automotive software section, rather than concrete over his rose garden that kept getting trampled on by lawers.

There was no software in mine posts.

[Brucehart]

All this talk of pumps. Im trying to differentiate thee difference between the 1.8 endura Na, td, and td intercooler derv pumps. Could anyone help.

[anke123]

Thanks for the files uploaded, really helped.

[befrak]

The pump in my car Ford Mondeo 1.8 TD mkII 1998 y is leaking when the motor is cold then it stops.
Is the Lucas/Delphi DPC8444B800A injection pump also used in this model?