Intercooled Tourneo Mk5

[dieselhead123]

This poor old van, 1996 Tourneo TD GLX in cayman blue came to us for repair in December 2009. The van was diagnosed with a faulty Epic pump and a number of other engine management issues. Unfortunately, the repair was not cost effective for the customer and the van was taken in part exchange for another from the sales front.

The old girl sadly sat in the corner of the yard for a year awaiting the arrival of a good pre-used Bosch pump. Sadly some parts were removed during it's stay

When the parts became available, we went to work!

The Bosch pump was fitted, the inlet manifold changed for an early unit. The water cooled egr unit was removed and the water pipes altered. The butterfly valve was removed from the turbo and a Mitsubushi L200 intercooler fitted over the engine. The intercooler thermostatic cooling fan was wired up and a throttle cable fitted.

The engine started first turn but smoked on tickover, the pump was dialed up to 0.68mm lift at tdc, perfect!
RPM was limited, to overcome this the 'power' screw was wound out about 10mm and the tickover reduced accordingly, however, this required the throttle pedal to be bent up in order to acheive full throttle. Additionally, the 'smoke' screw was wound in 1.5 turns.
To allow air flow through the intercooler, an Escort Cosworth bonnet vent was fitted and the triangular vent fitted in the wing to allow hot air to escape.

The overall result is good acceleration and excellent fuel economy, top rpm is still a bit limited, perhaps the next engine modification will be 100ps injectors

How it started out!


The wing and bonnet vents

[dieselhead123]

Some more pictures.

The early manifold and pipework


The intercooler

[turbotom]

hmmm thats got me thinking as ive got one of those intercoolers from a pajero i broke for spares.

[transitandy]

very nice m8

[psv-hgv-flt]

yes, deffo go with 100ps injectors (hell of a diffrence) but you will need to play with the pump again and reduce the fueling.

[dieselhead123]

hmmm thats got me thinking as ive got one of those intercoolers from a pajero i broke for spares.

That's what it is off and one of the pipes. The other pipe is from a 1.9td scudo/dispatch/expert with bits of the transit one joined in!

Have a go fella, it really does work

[dieselhead123]

yes, deffo go with 100ps injectors (hell of a diffrence) but you will need to play with the pump again and reduce the fueling.

Cheers for the advice on that one mate, will see if my injector supplier can mod them

[psv-hgv-flt]

yes, deffo go with 100ps injectors (hell of a diffrence) but you will need to play with the pump again and reduce the fueling.

Cheers for the advice on that one mate, will see if my injector supplier can mod them

best too get new set of 33710

http://www.uniteddiesel.co.uk/stanadyne ... ectors.php

[turbotom]

how is the ic fan wired up? i take it its supposed to cut in when turbo is under high presure?

[dieselhead123]

how is the ic fan wired up? i take it its supposed to cut in when turbo is under high presure?

Hi mate, the fan is wired up to the thermo switch on the intercooler outlet, the fan comes on when the intercooler reaches a certain temperature. The thermo switch is fitted to the mitsubishi intercooler as standard. Before the fan was wired up, the intercooler would get very hot if the van was driven hard and performance would drop off, the exit vent in the wing helps hot air escape from below the intercooler. Hope this helps

[transitandy]

This thread is getting interesting m8

[dieselhead123]

Today I found this

From a Toyota Landcruiser, 3ltr.
The good thing here is that it is a water cooled unit so should allow more boost to be sustained over a longer period
opinions/thoughts gentlemen

[dieselhead123]

Finally got round to fitting the Exhaust Temperature Gauge and probe. I wanted white face with blue illumination to match the mp3 stereo The matching boost and oil pressure gauges are going to be another four or five weeks from the supplier.
As these are a cheep brand, there is no separate feed for illumination, had I thought about this I would have sought confirmation from the supplier prior to purchase, beware
Once they are all fitted, I will 'break' into them and connect a separate supply to the lighting circuit, more work!

The probe in place, 1/8th bsp socket welded in the egr blank.


The illuminated gauge.

If only I knew how to work a camera

[dieselhead123]

Spent some time 'fettling away' manufacturing a four branch exhaust manifold for the larger turbo


'Sub' 17 seconds is getting closer

[dieselhead123]

Finally got around to completing the four branch manifold for the new water cooled turbo.

The waste gate actuator has been tested and operates at 14psi, the actuator linkage needs modification to provide clearance as both inlet and exhaust rotor casings have been turned and will be altered to provide an adjustment facility. The water cooling will be full flow and connected into the heater hose that runs along the edge of the rocker cover.
Just to add, the manifold was constructed from the exhaust manifold of a 1.8 zetec engined focus and will be available for inspection, should any of you be interested , at the forthcoming Reading build