Vehicle & Technical > Discovery

TD5 Intercooler into 200 tdi upgrade, i've made a start.....

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barmiebrumie:
Nathan, is there any change in peformance  :?: ,


Thanks

ne jones:
There doesn't appear to be, but i was told only to expect about 3-5 bhp from the ic change.
The real gains come from adjusting the fuelling and boost which i'd already done.
Does anyone know what would be a maximum safe boost pressure to run with this ic?
Currently running @ 14 psi but have heard 18 psi is ok?
Is it?

Dr Neil:
great pics Nathan, thanks!!

i noticed you didn't have to remove the fan cowling or move the radiator which was the two things i was concerned about.

I will have to start getting a few bits sorted and take the plunge!!

I noticed you asked about the boost. I have been reliably informed you can wind it up to 1Bar (.7 standard) or if your really brave you can open it up all the way as it will only boost 1.4 bar, though i wouldn't do it myself.

If you want a bit of extra oomph you could move the pick up point for the pipe onto the turbo actuator.Right here goes

1. disconnect the pipe that goes from the top of the fuel pump to the turbo actuator, then remove the Tpiece that goes into the turbo.
2.obtain a short bolt and copper washer to blank off the hole you have just left.
3.Remove the bolt that goes into the top side of the inlet manifold about half way along (just above the rocker cover).Get another bolt of the same thread and drill a hole down the centre of the thread and then from the side into the centre hole(alternatively you could try and buy one).Then obtain a banjo union to fit the bolt and two copper washers,and fit it into the manifold.
4.Obtain a T piece of the same diameter and some rubber hose,connect a short piece of hose to the Tpiece and join it to the banjo and secure with clips.Then from one of the other outlets of the Tpiece connect another piece of hose and join it to the origional pipe that comes from the top of the fuel pump and secure with clips.
5. You should now have one outlet of the Tpiece left.From this you need another short piece of hose connected to it.You then need some metal pipe to route through the exhaust manifold up to the Tpiece and connect it to the hose.At the turbo actuator use the existing short rubber hose and connect to the metal pipe.

You should now all be connected up (providing i haven't forgotten anything).The next step is to start up the engine and go for a spin!!!
And i can tell you it Does make a difference!! :D .

Whilst i have done this to my vehicle i cannot accept any responsibility if it goes bang or causes any damage(though i have been told it will be o.k)

I will take some pics and put them in my gallery when i get chance as it may seem clearer than all those words.

hope this helps

Nei....

ne jones:
Thanks Neil.

I used the car for getting some furniture from Ikea today and commented to the wife that it didn't seem to have 'much' pull. She also asked what that noise was? Since i mostly to music I hadn't heard any noise.

Went out tonight with no weight in the car other than my 19 1/2 stone and the car was definitely not pulling aswell as before the conversion. The boost was about 2 psi lower aswell.

I tightened some jubilee clips, got more torque on them with a large screwdriver and checked the pipes for splits etc.

What I found was the weld on the u-bend is blowing, my thoughts are that this is responsible for the loss in performance and the 'noise' SWMBO heard too.

I have got two 3" silicone connectors off ebay and when they arrive i'll replace the joint i know is blowing and if necessary the other weld too.

Probably be the weekend before I know whats what but i'll post the results on here.

Doing a run down to Newport Gwent on Sunday, then Monday up to Lampeter so I gotta cure it before then.

Dr Neil:
Have you tried re adjusting the fuel pump now that you have fitted the intercooler as now you have a bigger one you should be able to allow more fuel in without too much smoke, that is why when you have a performance intercooler fitted they adjust the pump afterwards otherwise you are cooling the same amount of fuel quicker instead of more fuel(if you know what i mean)..

hope this helps

Neil......

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