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Thread: TDI VNT Turbo Upgrade +++

  1. #1
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    TDI VNT Turbo Upgrade +++

    A few weeks back I received a Turbo Technics VNT turbo from Allisport. Today I took the defender out of action and started on the upgrade.

    This is not a straight forward turbo swap because my 'Defender' is actually a 1989 LR90 that has a Discovery 200tdi Engine under the bonnet. The difference between the Disco and Defender 200tdi is in the turbo position and timing case/ancillary arrangement. The Disco turbo/manifold flows better and as a result produces a few more BHP than the Defender arrangement. As it is now I am not benefiting from this because of issues with the exhaust downpipe and air intake.

    As part of the VNT install I plan to:

    - Remove air intake restrictions
    - Improve exhaust flow
    - Reduce under bonnet temps
    - Improve the brakes

    I went with the VNT kit for the 200TDI DISCOVERY from Allisport. It should all plug in with only the downpipe to modify.

    Here is the current configuration with the snorkel on LHS and the corkscrew downpipe.



    Because I installed a massive county AC/Heater unit on the LHS I had to route the snorkel intake between the inner outer wing, this meant a small diameter hose used only when wading. Not ideal!



    Removal of the snorkel has left a mess on the outer wing, so I will probably replace and repaint.

    The inner wings were galvanised from the factory back in 1989, but the galv has since been defeated!

    So I found some galvanised replacements. Missing some holes for the washer bottle but otherwise identical.



    Turbo out

    No play on impeller, although the leading edges look like they have copped a few strikes and the oil mist beyond the turbo is significant.

    To get an idea of how the new turbo sits I pushed it onto the manifold studs through the plastic - keeping it under wraps for now

    There is good couple of inches gained out the back, very pleased with this as I should be able to replace the corkscrew downpipe with a smoother bend.

    The intake sits a little lower and further forward than factory but looks good to clear the alternator.

    Plan is to run both inlet and outlet pipes along the top of the chassis rail, moving the PS pipe down the side of the rail and out of the way.

    This image also shows the down pipe provided with the kit - never gonna fit!



    Some weird residue in one of the exhaust ports - any ideas?


    EGT probe will be removed, plugged up and a new one tapped into the outlet where all ports converge.
    20171126_173413.jpg

    On the left the TD airbox that has been in place since the conversion. On the right a 300TDI box, much bigger! Will have to figure out where I can mount it.



    Manifold will be sent off to get ceramic coated inside and out, more to follow when it returns.

  2. #2
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    The weekend super storm that never really happened saw the 'workshop' AKA the two car garage , full with cars and no space to work.

    But there was time for progress in thought. Ive decided the air filter will be best positioned alongside the ac compressor, so zip tied it in and figured out a bracket






    This requires the PS resevoir to be shifted along to make space for the intake ducting to pass between it and the coolant tank.

    The air filter housing will get in the way of the scissor action bonnet stay so I will need to switch to a later td5/puma bonnet stay.

    Recieved a new EGT probe. Aussie made, closed tip 1200ms response time. Probe sheath is Inconel with teflon insulated cable. Stainless braid and fittings. Good up to 1100C.



    There were probes with faster response times but they were thinner or open tip which reduces strength and longevity. Last thing I want is a bit of probe to break off and grenade my turbo!



    The old probe position is filled with a 1/8 npt plug.



  3. #3
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    Quote Originally Posted by manic View Post
    The weekend super storm that never really happened saw the 'workshop' AKA the two car garage , full with cars and no space to work.

    But there was time for progress in thought. Ive decided the air filter will be best positioned alongside the ac compressor, so zip tied it in and figured out a bracket






    This requires the PS resevoir to be shifted along to make space for the intake ducting to pass between it and the coolant tank.

    The air filter housing will get in the way of the scissor action bonnet stay so I will need to switch to a later td5/puma bonnet stay.

    Recieved a new EGT probe. Aussie made, closed tip 1200ms response time. Probe sheath is Inconel with teflon insulated cable. Stainless braid and fittings. Good up to 1100C.



    There were probes with faster response times but they were thinner or open tip which reduces strength and longevity. Last thing I want is a bit of probe to break off and grenade my turbo!



    The old probe position is filled with a 1/8 npt plug.


    Looking good Manic. Do you have a boost gauge too? If so where is that connected? Who did u get to do the ceramic work?
    Cheers
    Travelrover

    Adventure before Dementia

    2012 Puma 90 - Black
    1999 Td5 110 Ute - White
    1996 Tdi 300 Wagon - White

    VKS-737 - Mobile 0972

  4. #4
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    Quote Originally Posted by travelrover View Post
    Looking good Manic. Do you have a boost gauge too? If so where is that connected? Who did u get to do the ceramic work?
    I have a Madman ems2 which I have had monitor boost before but I switched the input to oil pressure after seeing a steady boost pattern. The sender was tapped into the top intercooler pipe to inlet manifold but now im thinking of tapping straight into the intake manifold. Certainly need to monitor boost on my first run.

    The exhaust manifold has been sent to HPC coatings. Looking foward to getting it back!

  5. #5
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    It has returned, and it looks great!

  6. #6
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    Matt Sidetracked is my new name. I've started tidying up the wiring!

    To keep it on theme, I finished up with a new breather from allisport.

    Its supposed to be uncloggable and therefore good for the turbo. Im sceptical on its filtering capacity as it appears to be two tubes inserted into an aluminuim cylinder. BUT it is a quick and tidy fit compared to a provent. So there you go, hopefully some more progress on the turbo install before the year is out!

  7. #7
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    Any one have any thoughts on using a check valve and venting the crankcase breather output into the chassis rail instead of running it back through the turbo?

  8. #8
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    The parts to convert the bonnet stay to later td5/puma arrangement have arrived. Pretty sure that counts as progress...

  9. #9
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    New victor reinz manifold gasket , manifold loosly bolted on with turbo.

    Dipstick needed a bend to clear the turbo but otherwise all looking good.

    There is more space for dump pipe and a clear path infront to pass intake and boost along the chassis rail.

    The other concern was the AC blower unit. No issues there either. Plenty of clearance.

    This turbo is a much better fit, happy so far!

  10. #10
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    Low pressure PS hose was running along the top of the chassis rail. To keep this area clear for intake/boost pipes I have come up with the following.

    See photo

    Top: section cut off for disposal

    Middle: barb soldered on at the cut.

    Bottom: hose will run from barb, along the side of chassis rail, to PS pump

    ---

    Easier than bending a new pipe run, and it will do just fine.





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