Thread: Freddies D2a

Hi team,
I've owned my D2 for over a year now and I thought I'd report on my progress and results.
It's a 2003 D2a Auto TD5, and was bog standard when I got it (and as slow as a wet week).
Having read heaps of details from AULRO and done some research on what works for Diesel engines (this is my first), I have completed the following:
Full service from LRA - pricey but worthwhile, since they gave me a report about the sludge that came out of the gearbox and a few other items that were leaking, bent or broken.
I fixed all the items in the report:

• Rear diff oil seal
• Viscous fan bearing (replaced the fan too, for good measure)
• Replaced the bent steering track rod
• Replace the leaking steering damper
• Full service on the Auto (Footscray Automotive Automatics - top job)

Next, I fitted an EGT gauge (pre-turbo, in the middle of the manifold) and bought a second-hand Nanocom.
Then, I set about fixing all the 'passive' items that would improve the performance, in anticipation of a map upgrade:

• Tweaked the rod on the turbo relief valve
• Replaced the muffler with a 'straight through' item
• Deleted the cat
• Deleted the EGR
• Replaced the intercooler with a bigger one (Serk, from Paddock Spares, very nice unit - and BIG)
• Fitted a Provent 200
• Replaced all the turbo hoses with silicon

Having done all this, the car goes like a cut cat, and I'm a very happy Freddie.
"Incremental Gains" are something that I have learned about over the years, having built a very fast sports car and being a keen cyclist - it's not one big thing that brings the results but usually a combination of small items, working in harmony with each other.
I'm so happy with the car that, having been up to the High Country for a couple of weekends (one of which was pretty heavily loaded), I'm satisfied that I don't really need to take the next step of upgrading the fuel maps. I've come to this conclusion by watching and learning from my egt readings. I'm satisfied that, under nearly all circumstances, if I need more power, I just need to use my right foot. If I keep the boot into it for long enough, there are a lot of other things happening that should be limiting my enthusiasm - more fuel at lower throttle openings seems like a waste of time really. With my foot flat to the boards, I can still get the egt up to a level that is not good for the car so, more fuel at WOT would just burn or break something.
For the time being at least, I'm sticking with what I've got and planning on keeping this car in good condition for a long time.
Thanks to everyone who has posted information on here over the years and those who have helped out with PMs, AULRO has been an invaluable treasure trove.

Originally Posted by Phat-Customs

Nice cooler! Bet that was pricey!

It certainly looks the goods, doesn't it?
It seems cheaper than a re-map and, now that I've seen what the combination of 'easy-breathing' items can do, I'm happier than I think I would have been if I paid a heap to simply have more fuel pushed in.
When I add the cost of the items that I have put in to the cost of buying the car, all I've done is made a cheap car a bit less cheap.
I could have easily paid more for a similar car with 100kks more on the clock.

As an aside, I think that getting all the crud out of the air-con rad was probably as helpful getting the new i/c. That thing was choked and I'll be giving it some serious attention every year from now on.