Chip (and large intercooler?): TD5 2003 Disco2a

**discomarsh** · 12th August 2009, 01:33 PM

I know there's a wealth of knowledge on this forum about a chipping and larger intercoolers for TD5s.

I have a 2003 Disco 2a (facelift). If I understand correctly, it has a FLASH ECU chip, which means that a new fuel map can be uploaded onto it, rather than a new chip installed. I gotta say that I'm not terribly mechanically inclined (because of time more than inclination: I'm a slow learner).

There are a range of suppliers for fuel maps in Australia. I have three main specifications, regarding the modification:
- More grunt, primarily for highway driving, and secondarily for off-roading, and towing.
- Reliability. I plan to keep the Disco for a good while.
- Service by a good bloke (or woman, for that matter).

So my questions:
a) what suppliers do you suggest?
b) what advantages/disadvantages are there of getting a larger intercooler?
c) are any other modifications necessary to compliment a new fuel map or intercooler?
d) costs?

I live a couple of hours from Sydney.

cheers,
Discomarsh.

Shane_H · 12th August 2009, 02:01 PM

Hi discomarsh,

I'm not the one to give you technical advice but I have had a Syntek ECU remap in my 04 Disco TD5. I am very happy with it.

They are Brisbane Northside (better pack a sandwich for the trip). Brett Jones is the technical man to deal with. He has a selection of Landys himself.

Maybe worth an email or phone call to him.
Welcome to Syntek
Sales@syntek.com.au

I am not affiliated with the company just a very satisfied customer.

I got mine done during the holidays and actually spent time with Brett while he did my flash upgrade and also put a new chip into my mates TD5 Defender ECU. Interesting techo stuff for me.

As for intercooler upgrades I have no idea.

Cheers & Good Luck,

Shane H

**Fluids** · 12th August 2009, 03:03 PM

Hi Discomarsh.

If I'm not mistaken, the facelift D2a already has a larger intercooler (over the earlier D2 non facelift models). Possibly 30% larger area ?? (in same package size) but you might want to confirm that % increase.

I have a D2a 2004 Td5 Auto, so I've been checking out the options, and wanting reliability and long term ownership, means not going too overboard on the ECU remapping ... hence, a mild to medium remap on a facelift doesn't need a larger intercooler ... others may cut me down, but atm that's how I understand it.

Kev..

**discowhite** · 12th August 2009, 03:53 PM

fluids, you cant go overboard with an auto D2 due to the auto. i think they have a torque limit in the trans ecu.

as for a larger IC, i wouldnt bother in the update. as stated the IC is bigger than the EU2 IC's. the core is a different design and is thicker, length and width is the same.
the only mods after the upgrade would be, remove the main muffler and replace with straight pipe and remove the EGR system.
after that you WILL have a different car...you will love it even more

discomarsh..is your D2 auto or manual?

cheers phil

**Red Baron** · 12th August 2009, 04:43 PM

Give Tombie2 a PM on this forum or visit the Verandah section; he does the ECU re-maps, (he may even give a discount for AULRO members, but don't quote me)....can't wait 'till I can get one! BWARHAHA!!!! Chris.

**harlie** · 12th August 2009, 04:50 PM

If you have an Auto the TCU (Trans Control Unit) will drop the system in to Limp Home if you over do it – there is a torque sensor in the trans. A Stage 2 fuel map with the standard Intercooler will put it just under the limit (around 140/420) that the TCU will allow. So unless you have temp issues the intercooler isn’t worth the $ (in an auto).

I have a stage 2 (produced by BAS) fuel map sold and supported by tombie2 on this forum (Total Rover Tech) – very happy with it - and inlet temps are still quite low...

**discomarsh** · 12th August 2009, 04:59 PM

Originally Posted by discowhite

the only mods after the upgrade would be, remove the main muffler and replace with straight pipe and remove the EGR system.
after that you WILL have a different car...you will love it even more

discomarsh..is your D2 auto or manual?

Discowhite: I have an auto.

Thanks for the tip about the EGR system & muffler: I recall reading about that now. Who can perform that modification?

Cheers,
Discomarsh.

**discomarsh** · 12th August 2009, 05:03 PM

Originally Posted by harlie

If you have an Auto the TCU (Trans Control Unit) will drop the system in to Limp Home if you over do it – there is a torque sensor in the trans. A Stage 2 fuel map with the standard Intercooler will put it just under the limit (around 140/420) that the TCU will allow. So unless you have temp issues the intercooler isn’t worth the $ (in an auto).

I have a stage 2 (produced by BAS) fuel map sold and supported by tombie2 on this forum (Total Rover Tech) – very happy with it - and inlet temps are still quite low...

Harlie,

Thanks for the info about the TCU: hadn't heard of this issue before.

You mention a "Stage 2" fuel map:
- what others exist?
- who is BAS?
- does it reduce the turbo lag of an unmodified engine?

Cheers,
Discomarsh.

**Bytemrk** · 12th August 2009, 05:42 PM

Originally Posted by discomarsh

Harlie,

Thanks for the info about the TCU: hadn't heard of this issue before.

You mention a "Stage 2" fuel map:
- what others exist?
- who is BAS?
- does it reduce the turbo lag of an unmodified engine?

Cheers,
Discomarsh.

BAS regularly posts on here... very helpful guy.

Who is he... Bell Auto Services, B A S performance remaps chips and tuning for power and economy TD5 Vnt Turbo Conversion

As others have said... PM Tombie2

Cheers, Mark

**harlie** · 12th August 2009, 06:44 PM

Originally Posted by discomarsh

Harlie,

Thanks for the info about the TCU: hadn't heard of this issue before.

You mention a "Stage 2" fuel map:
- what others exist?
- who is BAS?
- does it reduce the turbo lag of an unmodified engine?

Cheers,
Discomarsh.

Stage 1 is a mild upgrade that most people do.
Stage 2 has a bit (noticeably) more. - I actually tried both 1&2 - can chop and change with nanocom...
Then if you have a manual he just keeps going all the way to 170+kw / 520+Nm (but you will need other changes to get here - IC, exhaust ect).

The stage 2 with the auto has absolutely no noticeable lag at all (egr removed but exhaust, IC & everything else factory). During normal driving the auto also changes up at lower rpm (torque sensor in trans) - fuel consumption is unchanged.

Some suppliers will give you a generic fuel map, Tombie2/BAS will match the ECU number / vehicle year / injector type and provide a modified map for that combination (there's heaps of combinations - ie. the fuel map file supplied for my car won't work well in your car unless everything is identical)

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