New Larger Intercooler TD5 D2

[Redback]

Well i installed a larger intercooler on Sunday, today i did 100k drive to Hurstville, Taren Point, Sutherland and back too Helensburgh, to say i'm under whelmed is a bloody understatement:twisted::twisted: at $900:twisted: and 4hrs of work:twisted::twisted: pulling the old one out and putting the new one in, i'd say not bloody worth it at all.

Know where near the 25% to 30% increase in power and torque they claim, I'm not very impressed about this at all, if it wasn't such a pain to pull it out and put the old one back in, I'd send the mongrel thing back:twisted::twisted::twisted::twisted::twisted:: twisted::twisted::twisted:

Baz.

[Slunnie]

Really?

I found mine gave about as much as what the chip did. It was installed the day after it was chipped.

[Redback]

Really?

I found mine gave about as much as what the chip did. It was installed the day after it was chipped.

Did yours have the chip modded again when it was installed:confused:

[dmdigital]

I found mine didn't give me a noticeable power increase but it made the acceleration so much smoother and knocked the turbo lag back from a kick up the rear at heavy acceleration that the remap had given me. There did seem to also be more torque too.

[discowhite]

20-30%?? who claims that?? thats flow rate increase not power baz.
an intercooler alone will never give that amount of increase.
there was a noticable difference in acceleration in the 90 when standard, made it drive like it did when it was really cold outside.
couldnt tell if there was an increase after the chip, but the chip is tuned for a TD5 with an intercooler.

also, you did test it out when it was quite HOT....

cheers phil

[Slunnie]

Did yours have the chip modded again when it was installed:confused:
No it was with the same chip, but that said the chip and intercooler were being done at the same time, and I drove it inbetween.

[Nathan]

If you want extra power from a diesel, go the gas injection option. Definately a noticable improvement AND the govt. pays for most of it!

[Redback]

The other thing was no noticeable drop in EGTs either, maybe I'm expecting too much, but for $900 I thought at least a bit of a difference, maybe the 3" will help a bit.

Baz.

[omvanders]

I had an upgraded intercooler fitted when I purchase my '99 300TDi a month ago... no noticable difference until I had it dyno-tuned. Pre dyno 50kW at the wheels, post dyno 70kW... love it!

[Tombie]

Baz...

Check your boost levels... Your most likely down on boost now!

You'll find a little tweak of the wastegate (do 1/2 turns ONLY) should bring you back up to speed...

[Slunnie]

Baz...

Check your boost levels... Your most likely down on boost now!

You'll find a little tweak of the wastegate (do 1/2 turns ONLY) should bring you back up to speed...
Hmmm, Davis did reset the boost on mine when they fitted the intercooler. I forgot about that.

[discowhite]

Baz...

Check your boost levels... Your most likely down on boost now!

You'll find a little tweak of the wastegate (do 1/2 turns ONLY) should bring you back up to speed...

dose that work on a D2? we tried that on barry's D2 last year, didnt make any difference to power or smoke.
i thought the D2's waste gate was regulated by the ecu??

cheers phil

[Xavie]

Could of the disgustingly hot day any have any thing to do with it or does it take a while for it to work properly?

[Redback]

Baz...

Check your boost levels... Your most likely down on boost now!

You'll find a little tweak of the wastegate (do 1/2 turns ONLY) should bring you back up to speed...
[quote=Discowhite]
dose that work on a D2? we tried that on barry's D2 last year, didnt make any difference to power or smoke.
i thought the D2's waste gate was regulated by the ecu??

Do we turn it clockwise or anticlockwise

Baz

[Tombie]

Increase max boost = shorten rod

Decrease max boost = longer rod

[rick130]

Baz...

Check your boost levels... Your most likely down on boost now!

You'll find a little tweak of the wastegate (do 1/2 turns ONLY) should bring you back up to speed...

When a mate was consulting to LRA back in '98-'99 they had a Storm engine on the dyno at Rose Hill and they increased the boost 1-2 psi and doubled the thickness of the I/C and they claimed near 20% increase in power/torque.

Almost seemed too good to be true, but I worked with him for a number of years and he never BS'd.

[Slunnie]

When a mate was consulting to LRA back in '98-'99 they had a Storm engine on the dyno at Rose Hill and they increased the boost 1-2 psi and doubled the thickness of the I/C and they claimed near 20% increase in power/torque.

Almost seemed too good to be true, but I worked with him for a number of years and he never BS'd.
Its a shame they didn't deliver them in that spec!

[rick130]

Its a shame they didn't deliver them in that spec!

Yep, that's what Mark said too.

[Redback]

So far i have gone 1 full turn on the wastegate with no real difference:no2:

I guess i just keep turning until it goes into limp mode and then back it off half a turn:eek::confused:

Baz.

[discowhite]

pull the hose of that goes to the wastegate modulator diaphram.
if this dosent make a difference you have a problem.

if it works you will over boost, the car will still drive but the fuel map will go to a defult setting, so the car wont be real responsive. turn the engine off and re start, that will reset the map.

marcel showed me this trick ages ago.

cheers phil

[LRHybrid100]

yup did mine like this ages ago, while on the phone to DW in Alice.

Pull the hose off the turbo, went into over boost at 1.3 Bar so shortened the rod to give a max of about 1.25 Bar - No Worries.

LRH

[Slunnie]

yup did mine like this ages ago, while on the phone to DW in Alice.

Pull the hose off the turbo, went into over boost at 1.3 Bar so shortened the rod to give a max of about 1.25 Bar - No Worries.

LRH
Is this how people are setting boost levels?

Keep opening it up until it over boosts and then bring it back a fraction to prevent it triggering.

[Tombie]

Is this how people are setting boost levels?

Keep opening it up until it over boosts and then bring it back a fraction to prevent it triggering.

Yep! Nothing wrong with it...

BUT... You need to try it loaded up on a hill if possible to make sure its correct under load.

[abaddonxi]

I think right about now someone usually says that you should have something to monitor exhaust gas temperatures.:D

Simon

[rick130]

I think right about now someone usually says that you should have something to monitor exhaust gas temperatures.:D

Simon

Only if you or the ECU is dumping extra fuel in.
Extra boost on it's own will reduce EGT's.

[Tombie]

I think right about now someone usually says that you should have something to monitor exhaust gas temperatures.:D

Simon

I think right about now it doesnt matter!!!

Increased boost increases air volume into the engine..
More air = Leaner so the ECU adds more fuel in proportion...

Go too far and overboost occurs and engines will lose power as the ECU places its inbuilt protection into action.

TD5s are a very intelligent engine / management system and the Lucas TD5 ECU is a brilliant piece of engineering... Far beyond the days of SIIIs and candle grade lighting :cool:

The ECU was a purpose designed marvel, with many capabilities and functions that were never even utilised... Like Active Engine Mounts - An NVH system that would control actively damped err.. Engine Mounts!

[rick130]

I think right about now it doesnt matter!!!

Increased boost increases air volume into the engine..
More air = Leaner so the ECU adds more fuel in proportion...

Go too far and overboost occurs and engines will lose power as the ECU places its inbuilt protection into action.

TD5s are a very intelligent engine / management system and the Lucas TD5 ECU is a brilliant piece of engineering... Far beyond the days of SIIIs and candle grade lighting :cool:

The ECU was a purpose designed marvel, with many capabilities and functions that were never even utilised... Like Active Engine Mounts - An NVH system that would control actively damped err.. Engine Mounts!

Would have been nice to see it further developed with a VNT, etc.

I suppose when it's all said and done, The Storm engine was designed around the time that the 300Tdi was introduced :o

[abaddonxi]

Sorry, and thanks.

Just remembered that I should have put a question mark at the end of that sentence.

:oops2:

Simon

[Redback]

Firstly i'd like to thank everyone for there help and advice, I have spoken to Bruce Davis and he backs up everything that has been said here.

I took the car for a drive yesterday, as it was cooler AND it did seem a lot better, the power does come on a bit sudden, but that's the nature of the BD chip, not having a flashable ECU it's something I have to live with I guess, but it's there, which is good.

Bruce has offered to upgrade his chip I have now, to the Chip to suit the intercooler as well as the other mods that he does, (he owes us an upgrade) once I've fitted the 3" and Vortex muffler, which is ordered, this will help reduce my EGTs, which Bruce reckons are usually high.

So all will be good soon, thanks again everyone:BigThumb:

Baz.

[Pedro_The_Swift]

and at Cooma there was all this talk of a D3,,,,,,
:ohyes:

[LRHybrid100]

I think right about now someone usually says that you should have something to monitor exhaust gas temperatures.:D

Simon

I have an EGT gauge on the dash and use the Nanocom in instrument mode to give me Boost levels - temps went down once I increased the boost.

I have Tombies mild > warm ECU upgrade and his larger intercooler and while towing the temps would rise quickly on a hill before I increase the boost, not bad now.

HTH

LRH

[Shaker]

pull the hose of that goes to the wastegate modulator diaphram.
if this dosent make a difference you have a problem.

if it works you will over boost, the car will still drive but the fuel map will go to a defult setting, so the car wont be real responsive. turn the engine off and re start, that will reset the map.

marcel showed me this trick ages ago.

cheers phil


Sorry to sound dumb, but do you take it off with the engine idling or stopped?
I assume then go for a drive & see if power has dropped, then refit hose, stop & restart?

[Gold_TD5]

As stated in an earlier post by myself, I can not hear my turbo spooling up at all any time.
Now I have the ecu upgraded, no centre muffler and the EGR eliminator kit fitted.
The car runs fine and I'm not really complaining on its performance.
BUT???
Could it be that my wastgate is opening to early and I'm not getting anywhere near maximum boost hence I don't hear the turbo spooling up???
As I have not driven any other TD5's bar my own, I have nothing to compare it with.
Some thoughts on this appreciated.
Thanks, Lionel

[discowhite]

Sorry to sound dumb, but do you take it off with the engine idling or stopped?
I assume then go for a drive & see if power has dropped, then refit hose, stop & restart?

easier with the engine stopped, but can be done at idle.
go for a drive and go easy with the right foot till you get to a cruising speed, you should notice the difference as you accelerate. if you give it to much stick the engine preformance will drop and will be noticable.
when it dose this change to netural, turn ignition off and re start motor. to get home or re connect the pipe and re start.

cheers phil

[discowhite]

As stated in an earlier post by myself, I can not hear my turbo spooling up at all any time.
Now I have the ecu upgraded, no centre muffler and the EGR eliminator kit fitted.
The car runs fine and I'm not really complaining on its performance.
BUT???
Could it be that my wastgate is opening to early and I'm not getting anywhere near maximum boost hence I don't hear the turbo spooling up???
As I have not driven any other TD5's bar my own, I have nothing to compare it with.
Some thoughts on this appreciated.
Thanks, Lionel

easiest thing is to fit a boost gauge or nanocom, or find someone else with a TD5 disco and go for a drive. the ecu will controll the wastegate and i dont think any of the aftermarket upgrades would tweek this value?

come to think of it i dont recall hearing the turbo in any of the disco's ive been in.....only defenders with vents...

cheers phil

[Gold_TD5]

Thanks Disco white, well I wound up up the waste gate actuator, definite lift in the go department, might have went a wee bit to far, I will just work my way back till I get right now.
Just got find a place who can supply and fit the mesh type exhaust connection.
Any ideas where in Melbourne this could be done.
Thanks Lionel.

[Redback]

Thanks Disco white, well I wound up up the waste gate actuator, definite lift in the go department, might have went a wee bit to far, I will just work my way back till I get right now.
Just got find a place who can supply and fit the mesh type exhaust connection.
Any ideas where in Melbourne this could be done.
Thanks Lionel.

Do a half turn at a time, I'm at one full turn at the moment, with a definite increase in power and not going into limp mode, I'm going another half turn when this rain stops and I can work on the car.

Baz.

[Shaker]

Do a half turn at a time, I'm at one full turn at the moment, with a definite increase in power and not going into limp mode, I'm going another half turn when this rain stops and I can work on the car.

Baz.

Are you shortening the rod?

[discowhite]

Thanks Disco white, well I wound up up the waste gate actuator, definite lift in the go department, might have went a wee bit to far, I will just work my way back till I get right now.
Just got find a place who can supply and fit the mesh type exhaust connection.
Any ideas where in Melbourne this could be done.
Thanks Lionel.

any exhaust shop, its all they use these days;)

cheers phil

[discowhite]

Are you shortening the rod?


page 2 post #15;)

cheers phil

[Redback]

Are you shortening the rod?


Increase max boost = shorten rod

Decrease max boost = longer rod

Baz.