Turbo upgrade

[Bmachining]

Not sure this should be here or in the modified section.

Finally getting around to doing a turbo upgrade on my 300Tdi! I thought of going the VGT type, but too easy and boring for myself.

I have a Compound Bi Turbo set up from a Mercedes Sprinter that should make a difference.

I have worked out the position for it, and have started on the new manifold flanges.

[Finnius]

Nice!
What's the advantage over the stock turbo? Faster spool up - more boost at lower RPM? More airflow in general?

[Bmachining]

It has 2 turbos, one small for low rpm boost, then the larger one takes over. No Lag at all when used on the Mercs, so should be the same with 300cc more capacity.

They have an exhaust bypass/wastegate between the exhaust turbines, but both are always spinning. And a bypass valve in the boost side between them also.
Seamless air delivery. I have made 2 dawes valves to control the vacuum actuators, and also have a boost pressure actuator from another turbo that i may try also to get the boost curve suitable.

[Bmachining]

Some progress pics.

[Bmachining]

Exhaust Manifold completed. Also support brace that bolts to where one was fitted in its original location. Other end bolts to 2 M8 threads on the side of the Block that were unused.

[gusthedog]

Have you got it together and on the road yet?

Be really interested to see how that type of turbo goes on a 300 TDI.

[Bmachining]

Not yet on the road. Its my daily driver, so i have to plan carefully when to work on it. Doing a workshop extension also atm.

Im really looking forward to getting done, i expect virtually no lag from idle which should make it very driveable and responsive.

I will post the progress as it happens.

What size front mount intercoolers are people using? Not alot of room in there. Im thinking of going for a same side inlet outlet setup.

[Cinqmars2]

Most common intercooler upgrade seems to be the double core Allisport ones - fits in the original spot with a bit of squeezing I think, may have to trim the top brace.

If you've got Facebook, and you're not already on it, check the Tdi Performance group run by fourby.co.uk - a wealth of knowledge there and I'm sure they'd love to see what you're up to with this!

Land Rover Tdi Performance Page (https://www.facebook.com/groups/243916606289320)

[Bmachining]

No reply for getting access to the Tdi group on facebook unfortunately. Was keen to see what others are up too!

Im waiting on components to make the exhaust system. Also the oil lines, one for each turbo.

Does anyone know the thread size for the oil feed gallery in the block? I should have checked it last time i had it apart.

[rar110]

I requested to join too. I took over a week to come back approved. Maybe check again.

[Bmachining]

Had a bit of spare time this evening so i modified the turbo outlet to face the right direction. Cut approx a an inch off the original and welded on a 90 degree bend.

Checked the oil gallery thread size, 12x1.5mm, And the oil drain, 22x1.5mm big enough to make a fitting to accept 2 drain tubes.

[Bmachining]

Job Done! Well almost.

After a quick test drive its looking promising. Max boost was 27 Psi, as fitted, i can adjust it up or down easily. Next job is to adjust the injector pump to increase fueling off idle to really kick the primary turbo into action. Also play with the primary wastegate between the 2 turbos, i think its opening too early.
Even used the original unmodified Air intake tube from the airbox.[bigsmile1]

[Bmachining]

Gradually finding a tune on it. Backed the Max boost down to 20psi, still not blowing black smoke, it previously used to under full throttle.
So far im getting 5psi at 1750rpm accelerating at 1/4 throttle, at 2000 its 15psi. More throttle bumps it up to 20psi. No smoke so i can keep increasing the low end fueling. Im after low end torque, has enough go up high for now.

I wonder how the boost curve compares to VNTturbos? Let me know!

Next is to upgrade from the factory intercooler.

[Bmachining]

More tuning and playing with wastegates. I now have Zero turbo lag! Soon as you let the clutch out and start accelerating there is at a min 5 or 6 PSI of boost, No matter how low the revs.
Pulls like a train! Towed a trailer loaded with near a ton on it and there was no loss of acceleration. Low down Torque is massive!

[shack]

Well done... I'll drop mine off on Tuesday to get the same treatment!

Towing is the real tell of real world performance, I guess that comes down to torque, which is right in the turbo diesel wheelhouse.

Be interested to see some fuel use figures/ dyno chart if you ever go that far...

Cheers
James

Edit: I occasionally tow a 7x14 trailer with about 1.5 tonnes on it, so that equals about 2.5 - 3 all up, mine certainly knows that it's on the back, one of the bigger issues I have is keeping it cool in summer, I'll be interested to see how you go.

[discorevy]

I wonder how the boost curve compares to VNTturbos? Let me know!

Next is to upgrade from the factory intercooler.

Nice work, I bet you're stoked , I know I would be.
The boost curve and characteristics sounds very similar to the VGT I have on my TD5.
You will definitely need to upgrade the intercooler as one of the results of the constant boost is higher intake temps, ( on mine they went up by around 10% at 110kph, but similar on full throttle )
Don't know if you have an EGT gauge but the other result of the higher flow and boost at medium throttle is substantially lower EGT's than fixed geometry turbos

[Don 130]

I hope you've got a reliable temp gauge instead of the original. You might have trouble keeping it cool enough as summer approaches, especially when towing.
Don.

[Bmachining]

Im very happy with the outcome!

The factory Temp gauge never moves[smilebigeye] Disconnected it and replaced with an aftermarket one. I also have a separate Head temp gauge with an alarm, homebuilt watchdog type. So far EGT hasnt gone above 550 C, No big hills around here to test on, besides a few sand hills!

Summer heat will be interesting, usually runs around mid to high 90C with Aircon on. When i get a front intercooler fitted it will certainly restrict airflow somewhat, But leaves room for a wider radiator... Are the V8s bigger?

I think fuel consumption will increase from the usual 10-11 Lt/100 round town, that lowdown torque feels great with its push in the back hehe

[Bmachining]

Update, of sorts. Setup is going great. It is so much more fun in soft sand now, no real need to worry about being in the correct gear to get up a hill anymore, Boost on tap!
Fuel consumption has not changed at all, Still getting 10.5Lt/100km with lots of around town driving, towing trailers and some sand driving all included.

Im still to find and fit a larger intercooler, then i might add more boost and fuel in the upper RPM range. Looking at options atm.

[rar110]

Im starting to look at intercooler/turbo options as the 200tdi rebuild progresses.

I’d be interested in what intercooler you choose. I was leaning toward the full width option.

[Bmachining]

I still have not upgraded the intercooler. Thinking of either a not too big front mount or making a thicker one for the original position. Even thinking of a water to air unit.
I did check air temps across the original, normal driving it coped ok, full throttle acceleration through the gears the outlet temp rose to over 140C. Sand or hard offroad driving would be similar high temps i would think.

[rar110]

Thanks. I will finish motor rebuild, and drive it for a bit.
But am thinking of Airtec or Allisport. Airtec is cheaper.

I have AC so will be double core option.

WTA IC has definite efficiency advantages. I guess I should look at that option. Im not sure if 200tdi Bosch injector pump has potential to deliver to make WTA potential worth while. I think double core ATA IC is about max potential for more power.

Brett’s feedback from a while ago is interesting.

Defender Intercooler Upgrade - Installation and Review - YouTube (https://youtu.be/0H3s-JlcXYc)

[Bmachining]

Finally Finished my intercooler upgrades.

First was to replace the original with a thicker core unit, this made a noticeable difference in throttle response, the original is rather restrictive.

Second, and a lot of work, is the water to air unit. I cut down the original manifold, cleaned up the runners as they are rather restrictive with a large bump in the lower port section, and around the bolt holes.
Fitted a 600*200*50 radiator behind the grill, and a 12V auxiliary pump to circulate the coolant.

Engine is noticeably smoother with the large Plenum volume. I havent yet checked temps of intake charge, but after a run the exposed end of the water core are much colder than the rest of the
unit. Also much colder than the Outlet side of the air/air intercooler.