Finally got her back together this arvo.
WOW what an improvement.The low and mid range response is greatly improved,even got the TC to cut in on the dirt in 2nd gearHopefully all this regained power will also equate to regained economy.
Over the last 3 weeks she has had the following long overdue work done.
All fluids/filters changed
Drive belt
Glow Plugs
Oil pressure sender
Provent
All cooling system hoses changed
Nanocom/3 amigoes banished
EGR removal kit
Exhaust gasket
Manifold webbing removed and 6 outer holes drilled larger
Wastgate adjusted,more adjusting to try.
Intercooler/radiator cleaned inside and out,AC cleaned.LOTS of caked mud in all 3
Engine Saver.

Im putting the performance gains down to a combination of the following.
Repair of leaking exhaust manifold.
Adjustment of wastegate.
Thorough Cleaning of the 3 radiators.
EGR removal.

An interesting point with the manifold.It WAS warped,around 3mm in total.After cutting the webbing out it was less than 1mm so I didnt bother getting it machined.Removing the webbing definately de-stresses it.I used a 5" grinder with a mega line disc.Just cut wedges out till I couldnt anymore then put on a grinder disc to tidy up.Half an hour including drilling the stud holes bigger on the 6 outside holes.

Off on an overnite camping trip tommorow,hopefully she appreciates all the attention and behaves!!!!
Andrew

__________________
LandyAndy

FAT BAZ,REST IN PEACE MATE!!!!!

Black Betty 1999 TD5 Disco and matching DIY off-road trailer
Classic Rangie(her ride) warm4.6,LPG,Wolf management,F/R ARB lockers
The Toy Series3 109 302V8 Auto(Project)
Stage1 V8 Van

Great to hear Andy, nice feeling when everything works out and there is a noticeable improvement

__________________
Disco TD5 Auto, CDL Reinstated, chipped, dual batteries, snorkle, 2" lift, 32" BFG Muds, Front and Rear Lockers and 4.11 Ratio's and a beer fridge...

Good News, Andrew!

We'll see you there, but won't be camping.

__________________
'05 D3 TDV6 HSE
'99 Subaru Forester Ltd (2" lift)

Great,see you tommorow.We are getting there after lunch in Collie,Graz is meeting us here.
Andrew

__________________
LandyAndy

FAT BAZ,REST IN PEACE MATE!!!!!

Black Betty 1999 TD5 Disco and matching DIY off-road trailer
Classic Rangie(her ride) warm4.6,LPG,Wolf management,F/R ARB lockers
The Toy Series3 109 302V8 Auto(Project)
Stage1 V8 Van

Much nicer vehicle to drive.Just did a 300km round trip,fully loaded with the camping gear and the 3 of us.Lots of hills,even holds 5th better @110 on the hills.
Fuel economy may be back,gauge between first and second mark.
1.10 bar was the highest boost I saw.Handy having the boost figure,you can let the pedal out just a tad and use less boost,will help with economy no doubt.
Andrew

__________________
LandyAndy

FAT BAZ,REST IN PEACE MATE!!!!!

Black Betty 1999 TD5 Disco and matching DIY off-road trailer
Classic Rangie(her ride) warm4.6,LPG,Wolf management,F/R ARB lockers
The Toy Series3 109 302V8 Auto(Project)
Stage1 V8 Van