Here's Some pics of what I did to my injector pump

just a word of warning, if you do these mods be aware that you could potentialy damage your engine if not done correctly and the pics are of what I did to mine so please don't blame me if it all goes tits up, thanks

looking from the drivers side wing you will see the top of the pump like this

18b02501.jpg


Under the cap in the middle of the cover is the smoke screw, this will affect low boost and is a must for all autos. Lever the cap out then mark the torx bolt in the middle of the locknut to the pump body, loosen the locknut so the bolt will turn free and turn the torx bolt in 1 1/2 to 2 turns clockwise then tighten the locknut. Try it up the road to see if it smokes too much, if it does back it off until it stops smoking.

Once that's done remove the 4 screws from the top of the cover( mine had 2 screws and 2 torx that hold the throttle position sensor on)
The cover should pop up on it's own, try not to twist it side to side as you don't want to alter the position of the diaphram that's below it.
Move the cover out of the way and leave it hanging on the pipe to reveal this

79a75f38.jpg


you should see a little pop mark on the inner part of the diaphram mark this to the pump body so you know where to put it back to.
Pull the diaphram out and you will see it looks like this,the score mark on the taper at the end is where the fuel pin rides on,if there is two marks it has been adjusted before

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then if you look in the pump where you took the diaphram out you will see a spring,plastic collar and the star wheel like so

ae8750b8.jpg


take the spring and collar out and for fcuks sake don't loose them!*
Mark the star wheel to the body so you know the original position and turn it clockwise 1/4 of a turn at a time(you'll have to build it all back up and try it up the road) if it dose'nt smoke turn it another 1/4 of a turn.
I turned mine one full turn (360 degrees) any more and it started to smoke too much. To turn the star wheel put a screwdriver between the star wheel and the pump body and gently flick it round.

The star wheel adjusts the automatic fuel control

c2973382.jpg


Now you need to take the cover off again and turn up the full load fuel delivery by adjusting the diaphram. It needs to be turned clockwise between 90 and 120 degrees,start at 90 and see how it is if it dosn't smoke too much go some more.

I moved mine from this position


79a75f38.jpg


to this


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and that's it,easy! :D

you could do all these adjustments at once but if it smokes badly you won't know which to back off

It's still too early to tell but if anything I'm getting better mpg although because I've loads more power now I've got my foot down more! So when the noveltys worn off I'll be able to work it out better

If you look at the links I put in post 4 it explains it all in detail and will give you a better understanding of what to do
"Happy tweeking!"

Excellant post very detailed
 
Only kidding. Well worth every penny of the 6k I spent on it. ;)
Been thinking about a TGV for a year now, think it will be the last thing done.
What sort of pulling power do they have over a 300tdi. Do they cruise at 70-80?
Mine at 70 uses a lot of fuel and I have disco transfer box. MT tyres don't help I know, they will be changed soon
 
Been thinking about a TGV for a year now, think it will be the last thing done.
What sort of pulling power do they have over a 300tdi. Do they cruise at 70-80?
Mine at 70 uses a lot of fuel and I have disco transfer box. MT tyres don't help I know, they will be changed soon


Aerodynamics is the single biggest problem for cruising at higher speeds - an engine change won't alter that.

A TDi 300 will cruise all day long at 70mph without using too much juice if it is regularly and fully serviced. When was the last time you changed the air filter? Have you De-catted and De-EGR'd yours.

£6000 for a TGV or £6 for a new filter - I know which I would try first.
 
Just done this to my 300 manual and its made a big difference on med to full boost (maybe a little smokey on mediium so I guess the star wheel needs bringing back a bit)

Pre boost ive noticed nothing as yet but ive only gone around 180deg in with the smoke screw, think i'll send that in a little more and see what I can get out of it.
 
What sort of pulling power do they have over a 300tdi. Do they cruise at 70-80? Mine at 70 uses a lot of fuel and I have disco transfer box. MT tyres don't help I know, they will be changed soon

The standard TGV is 135bhp and 277lb/f. I've now got a full width Allisport intercooler and 180 degrees on the diaphram. I guess well over 150bhp. It pulls better than my old 3.5 RRC or the same RRC with a 3.9 in it. Cruises well, especially considering it is on 315/70/17s (34.5").

£6000 for a TGV or £6 for a new filter - I know which I would try first.

I fitted a £6 air filter but it didn't cure the failed head gasket, cracked block, constant EDC related electrical problems or turn the turbo into a variable nozzle turbo. :D:D
 
Aerodynamics is the single biggest problem for cruising at higher speeds - an engine change won't alter that.

A TDi 300 will cruise all day long at 70mph without using too much juice if it is regularly and fully serviced. When was the last time you changed the air filter? Have you De-catted and De-EGR'd yours.

£6000 for a TGV or £6 for a new filter - I know which I would try first.

Mine has a service every 6 months!!
Has full length allisport intercooler and rad.
De-cat
De-egr
Pump tweaked
TURBO STOCK!! (last one blew)
And disco transfer box
 
I've already got the full width intercooler and am looking at getting the full width rad next month.
Did you find that the rad made any noticeable difference at all?

In the height of summer at billing this year, I pulled a caravan there and back and the guage didn't move above half at any point.
I fitted a kenlow fan to the rad before fitting to 90 as its easier, brought the kenlow wiring kit and temp sensor at billing but still not fitted it yet!!

Are you getting the alli rad surround too?
 
How did you fit the intercooler if yours is a auto?
Don't you have air con or oil cooler for the gearbox in the way?
 
How did you fit the intercooler if yours is a auto?
Don't you have air con or oil cooler for the gearbox in the way?

No air con on mine and the oil cooler sits far forward enough for it not to be an issue.
They're making me a custom made oil cooler too as I want to mount it higher as the winch currently sits directly in front of it.

No plans to buy the ali surround as I see very little point in it.
 
Cheers for the pic.

Do you think it was worth the outlay?

As been looking for a suitable 2nd hand intercooler, but they all have the connections one at each side, so a lot of pipework will be needed, and really need them to be on the back to fit better, like in your pic.

Makes a lot more room without the fan....did you put it back on, or go with an electric one?
 
Got any pics of the fitted intercooler, as I was thinking of doing this mod

And if you do go for a full width one, make sure you fit it from the rear and not the front. Not enough room to maneuver it into place from the front. :(
 
Cheers for the pic.

Do you think it was worth the outlay?

As been looking for a suitable 2nd hand intercooler, but they all have the connections one at each side, so a lot of pipework will be needed, and really need them to be on the back to fit better, like in your pic.

Makes a lot more room without the fan....did you put it back on, or go with an electric one?

I brought mine second hand at less than half price. It's the way to go if you can source one.
Saying that, if I had to do it again in the future for whatever reason and couldn't source a second hand one - on the basis of how this one has performed I could justify buying a new one at full price.

Coupled with the fuel pump mod I'd say I'd say it's definitely worth doing.
It has improved the driveability no end, in my opinion. Generally seems a lot less effortless and marginally better on fuel too.
 
what did you do with your fan setup - as looking to overhall the front end and might switch to electric if I get it all done - been told a mondeo fan works well :confused:

Just need to get the old viscous fan off tho - anywhere best to get the spanner from?
 

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