straight through 3" air intake ducting

[jbe]

Quite a while ago, I pulled out the air intake ducting on my Td5 Defender to properly seal it. I was quite stunned how convoluted and especially how restrictive it was. The narrowest section of it turns out to be just two inches at the water trap y-piece.

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I was never convinced that the factory intake would seal properly and therefore, I decided last week to replace it with a one piece 3” flexible hose from the snorkel to the air filter box. I used a 2 ply flexible silicone hose (1m) with an integrated metal coil. It is a very tight fit and I had to protect some areas from rubbing with some 4mm rubber pieces (at the edge of the ABS modulator bracket and underneath the steering rod). I also decided to put a heat shield on where it is close to the motor.

I always suspected that the factory air intake would severely restrict the engine performance, especially with highly tuned engines. My expectation was to get a little bit more power/torque in the low rpms. This expectation didn’t quite materialise, but the engine pulls noticeably better from 1700 rpm onwards and I am happy with the outcome.

[Flexo]

I'm in the same process right now after discovering the factory hoses were split so the snorkel was good for F.A

Do you have any photo's of the pipe installed? I was thinking along the lines of the same thing but it didn't look like it would have the clearance under the steering shaft?

[rick130]

Did the same on a Tdi fifteen years ago, including cutting off the restrictive neck on the Safari snorkel.

The bum dyno didn't detect any change, but then the fuel was turned up, a 3" exhaust made and installed, etc. so I'd reckon it had to help.

[jbe]

I'm in the same process right now after discovering the factory hoses were split so the snorkel was good for F.A

Do you have any photo's of the pipe installed? I was thinking along the lines of the same thing but it didn't look like it would have the clearance under the steering shaft?

I’ll give it a go. Problem is the spaces you can’t even see.

[jbe]

Did the same on a Tdi fifteen years ago, including cutting off the restrictive neck on the Safari snorkel.

The bum dyno didn't detect any change, but then the fuel was turned up, a 3" exhaust made and installed, etc. so I'd reckon it had to help.

The ABS modulator and its plumbing make it really difficult. What kind of pipe did you use?

[rick130]

No ABS on a Tdi! [emoji23]

It makes it really straight forward.

[jbe]

No ABS on a Tdi! [emoji23]

It makes it really straight forward.

I wish it was possible to legally de-ABS a car in NSW. The Wabco system in our trucks is crap and dangerous in some instances.

[rick130]

I wish it was possible to legally de-ABS a car in NSW. The Wabco system in our trucks is crap and dangerous in some instances.Really?
In what way?

I'm driving a D2 these days and find the ABS pretty good, and much better than the work BT50's and Hilux's.
The ABS programming is probably different, the TC is a lot more refined in the Disco compared to a Deefer.

[jbe]

Really?
In what way?

I'm driving a D2 these days and find the ABS pretty good, and much better than the work BT50's and Hilux's.
The ABS programming is probably different, the TC is a lot more refined in the Disco compared to a Deefer.

On road, I think the ABS /TC is not too bad in general, but I think that the software has a very poor or non-existent exception handling.

An intermittent issue made the TC go crazy in the middle of the Harbour Bridge; it applied the brakes randomly. At the time, the car was new to me and I didn't know where the ABS fuse was, but I made it to the offramp. Lesson learnt: regularly check for fault codes and fix sensor issues immediately.
On another occasion, I drove a very steep downhill section (30-35 degrees) and I had to stand on the brake pedal really hard.
Without warning, the ABS let the brakes go completely and I was lucky that I was in 1st low which prevented the truck from acceleration downhill. I read that this was a common problem with the early ABS Discos, but did not expect to come across in a 2005 model Defender. Not a good experience.

[JoeFriend]

I did this recently while doing a complete engine swap in my TD5. I also cut out the vortex thing and opened the pipe in the air box

It's the old problem of needing an extra joint in your arm, but unsurprisingly a lot easier without the engine in!

I just used dynamat on the areas affected by the steering shaft, cause it's stick on and I can be a bit lazy at times. The metal top should increase longevity as well.

No idea about the bum dyno, cause I installed an allisport intercooler at the same time.

[jbe]

I did this recently while doing a complete engine swap in my TD5. I also cut out the vortex thing and opened the pipe in the air box

It's the old problem of needing an extra joint in your arm, but unsurprisingly a lot easier without the engine in!

I just used dynamat on the areas affected by the steering shaft, cause it's stick on and I can be a bit lazy at times. The metal top should increase longevity as well.

No idea about the bum dyno, cause I installed an allisport intercooler at the same time.

Any chance, I could have a look at how you did it (I live very close to you)?

Cheers
Joachim

[JoeFriend]

Any chance, I could have a look at how you did it (I live very close to you)?

Cheers
JoachimI think I haven't updated my address, I am down in Wolli Creek now but sure thing.

And I am assuming you are asking me about the airbox and intake mod, not the engine swap!

[jbe]

I'm in the same process right now after discovering the factory hoses were split so the snorkel was good for F.A

Do you have any photo's of the pipe installed? I was thinking along the lines of the same thing but it didn't look like it would have the clearance under the steering shaft?


I took some photos, but it is really hard to take a picture that show the tricky bits.
The important bit is, the pipe clears the steering rack and is protected with a rubber mat from the steering rack and from the brake-lines rubbing through the pipe. It is an extremely tight fit. If you use the rubber z-piece on the safari snorkel, you could run a 2.5" pipe and a 3"-2.5" reducer on the airbox side. No idea what the difference in engine performance might be. Happy to talk if you need more info


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[Mark130]

Hello All,
Just checking no TD5 owners have found a better solution for this problem.
I have a 130 so no ABS, but have also replaced with silicon hose (thanks Nugget)
and will also need to enclose the silicon hose with rubber or teflon as it passes behind steering arm.
I can't see another solution, and no other route it can take.
Just wanted to check??

[Discofender]

I used this product after removing the original pipes......which probably had this hole when I drove through the Brisbane floods last year.

My Car Performance Silicone 2 Ply Air Ducting - 76mm - Red Air Intake Hose - 1 Metre (https://mycarperformance.com.au/air-ducting-filters/air-ductings/silicone-2-ply-air-ducting-76mm-red-air-intake-hose-1-metre-to-4-metres.html)
https://uploads.tapatalk-cdn.com/20230203/5d643c0b8a9a59963e8fbb6561e12c11.jpg

[akelly]

dealing with this exact thing on my 130 now, both hoses are completely stuffed, god knows for how long because they look fine from the top.

Is everyone just using standard worm drive hose clamps at each end? How do they go with the wire coil in the hose? I was thinking I might run some RTV around the inside before clamping them down.

[Discofender]

I used t bolt clamps to spread the clamping force across more of the hose.

Also planned on using rtv to seal but my test fit has ended up semi-permanent...... I was also concerned that the 2ply hose was a little thin and wouldn't stand up to much abrasion and could easily get an unseen hole (below potential waterlines). I have been looking at wide silicone or vinyl tapes to reinforce the hose.

Guess I might remove the snorkel and take out the hose this weekend.....

[Discofender]

So finally, I got around to a more permanent fix for the 3 inch air intake, I wrapped the entire 2 ply silicon hose with a layer of SOS silicone tape for an added layer of durability, four rolls! The silicone tape allowed me to shape the pipe around the bends it needed to..... also replaced the standard airbox with one from Alisport. Very well made, increases the surface air of the filter element to hopefully feed my hungry VGT a little better.

Cheers Discofenderhttps://uploads.tapatalk-cdn.com/20240110/84eca400337028e408667695c9de21c3.jpghttps://uploads.tapatalk-cdn.com/20240110/b15eb5bfc630d22e6addba45950431b6.jpghttps://uploads.tapatalk-cdn.com/20240110/d008e55f9b9f4510e969afe1968e7d14.jpg