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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.
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]
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.
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!
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.
Nice work, I bet you're stoked , I know I would be.Quote:
Originally Posted by Bmachining
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
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.
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
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.
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.