200Tdi Boost

[rocket_rod]

Hi all,

I have been looking around for some info on the 200Tdi. When we bought the 'fender the previous owner had fitted a boost controller and after looking on some websites I am just wondering about what boost is ok without affecting reliability. At the moment it spools up no probs and drops off the end of the boost gauge (15psi) fairly easily. I reckon at full load it might be pushing 18psi and seems to run just fine. 'Daisy' is going to take us around Aus, so reliability is the be all and end all, however if running 5 pound extra over standard (or close to that) does not affect reliability then I might leave the boost controller alone. We have a larger intercooler and it runs nice and cool, but don't know what to check for re. fuel pump mods that the previous owner also might have done that might come unstuck.

The specs that I have found for the 200Tdi:
84kW @ 4000rpm (is this the hard limit??)
198Nm @ 1800rpm
0.82bar (12psig) measured at wastegate according to the manual?

Any suggestions, help or experiences of additional boost (and limits)?

[justinc]

I would without hesitation fit a Pyrometer to check the exhaust gas temps as this has the most bearing on engine longevity/ reliability.
200Tdi's can handle 18psi quite happily with a decent intercooler, and if you fit a pyro upsteam of the turbocharger it is safe to run to 700degC for short periods. IMHO I would be happy setting fuelling so that 600C is a max for reliability etc. Stock fuelling will give about 500C max usually.


JC

[rocket_rod]

Call me a dunce, many have before, but when you say upstream you mean between the exhaust manifold and the turbo right?

Maybe I should look before I ask but is there an easy home for a pyro before the turbo exhaust housing?

Also wondering if the 400rpm is the hard cut/limit. I have no need to get there but curious...

[justinc]

Call me a dunce, many have before, but when you say upstream you mean between the exhaust manifold and the turbo right?

Maybe I should look before I ask but is there an easy home for a pyro before the turbo exhaust housing?

Also wondering if the 400rpm is the hard cut/limit. I have no need to get there but curious...

The only stupid question is the one never asked:D Yes, upstream is between the manifold and the turbo. You can drill and tap a small BSB thread for the pyro adapter easily in the 200Tdi manifolds, either Disco or Defender. Max revs are a waste of time with diesels IMHO, you need to get the fuelling/ boost happening as low down as practical, say around 1800 to 2k with a Tdi.

JC

[rocket_rod]

Cheers JC.

No arguement here about the revs, after buying the defer I have found that I'm not in much of a hurry :D. Asking about the revs because when I went through a fairly major roundabout the other day I could not find nothing except angel gear, eventually found 2nd and the poor motor flicked round to 3500+ and it sound like the motor had hit the soft cut. More that anything I want to put a mark on the tacho that says 'if you like me then don't go past here'.

Matt.

[camel_landy]

One of the main differences between the 200TDi and the 300TDi is the boost pressure...

200 - 0.7 bar
300 - 1.0 bar

If you up the boost pressure, I'd also suggest you change the spring in the top of the fuel pump for a 300TDi one. That way, the pump won't max out its boost too soon.

HTH

M

[justinc]

One of the main differences between the 200TDi and the 300TDi is the boost pressure...

200 - 0.7 bar
300 - 1.0 bar

If you up the boost pressure, I'd also suggest you change the spring in the top of the fuel pump for a 300TDi one. That way, the pump won't max out its boost too soon.

HTH

M


M,

I have been wondering if there is a way of obtaining a selection of springs, as I have noticed at least 3 different free length and wire diameters from disco and defender pumps, and D1 auto ones are different to manual ones too. Also, there seem to be a few different colour codes on them, I have seen blue, green and plain silver. There is a part number from Bosch on each spring too, but I have no scale or list/ catalogue of springs so i can use them as a selection chart, rather like Holley carb secondary actuator springs or SU needles etc.

Any ideas?

JC

[rocket_rod]

I haven't had a whole heap to do with diesels before now. Been searching and reading. Am I right in assuming that the top spring is the govenor spring?

I will search the tech pages now.

As I said reliability over horses for us and to be sure I wound down the boost controller. Did not seem to be leaning out or anything silly like that at full load, and she was running cool as a cucumber.

Have started looking for a pyro and no easy place so will have to drill and tap into manifold (meaning turbo off). This might have to wait 'til back in Adelaide where I can park in friends garage to play around, the street is no place to be pulling bits of engine off (and dropping bolts).

Any other help and advice is appreciated, cheers.

Matt.

[camel_landy]

M,

I have been wondering if there is a way of obtaining a selection of springs, as I have noticed at least 3 different free length and wire diameters from disco and defender pumps, and D1 auto ones are different to manual ones too. Also, there seem to be a few different colour codes on them, I have seen blue, green and plain silver. There is a part number from Bosch on each spring too, but I have no scale or list/ catalogue of springs so i can use them as a selection chart, rather like Holley carb secondary actuator springs or SU needles etc.

Any ideas?

JC

Have you got the Bosch VE pump manuals? If not, I have a .PDF version which I can ping over but it's 1.7M...

There's quite a lot of detail in them about how the pump works, etc... Although there isn't a list of different spring parts, I would have thought that Bosch would have a manual/pick list which details each of the parts somewhere.

M

[justinc]

Have you got the Bosch VE pump manuals? If not, I have a .PDF version which I can ping over but it's 1.7M...

There's quite a lot of detail in them about how the pump works, etc... Although there isn't a list of different spring parts, I would have thought that Bosch would have a manual/pick list which details each of the parts somewhere.

M

Thanks, I'll PM my Email address! About the list, I agree I reckon they'll have some info about springs SOMEWHERE:( I asked a diesel pump repairer this Q a while back and got a 'why do you want to do that?' answer:( -No sense of adventure:D

JC

[Red90]

Bringing this back from the dead... Anyone ever find a source or part numbers for different springs?

In my testing the stock Defender 200TDI spring bottoms out at stock boost.

[LowRanger]

I wouldn't mind knowing what the 300TDi spring part No. is,as my 200Tdi will happily hit 21Psi under full load:D