Intercooled Tourneo Mk5

[dieselhead123]

Progress has been a bit slow, customer's work has to take priority

Still sourcing water fittings for the chargecooler pipework, two weeks waiting for a delivery, only to get a refund from the seller, obviously they never had them in stock in the first place

Some more ordered this evening perhaps a plumbed-in chargecooler for the weekend!

TIM

[dieselhead123]

Great news!!!!

Had an email yesterday...
My new turbo is 'in transit', or whatever the courier is driving

TIM

[ColinJack]

My new turbo is 'in transit', or whatever the courier is driving

I like that comment!

[dieselhead123]

Been a bit of a mad rush this week on the Chucklebus, been busy with customer's work, but finally got to fit the new turbo!

The chargecooler has been fitted on the N/s inner wing, where the second battery would go and is all plumbed in!

Started first compression, but then it is a Di

Warmed up a bit to check for leaks on the chargecooler water pipes, then give it a rev.

Max 'no load' boost is showing as 18psi!

Pics a bit later!

TIM

[ColinJack]

Been a bit of a mad rush this week on the Chucklebus, been busy with customer's work, but finally got to fit the new turbo!

The chargecooler has been fitted on the N/s inner wing, where the second battery would go and is all plumbed in!

Started first compression, but then it is a Di

Warmed up a bit to check for leaks on the chargecooler water pipes, then give it a rev.

Max 'no load' boost is showing as 18psi!

Pics a bit later!

TIM

Well done!

[dieselhead123]

Finally enough internet 'things' to upload pics!

Those of you who were able to get to Transitmania will have seen the van, it made it to the show, completion was only acheived at about lunch time on the Friday before the show.
Load up and go!

My new promotional sticker;


Some pics of the installed chargecooler installation;

The second header tank is for the chargecooler radiator.


The power steering bottle has been re-located to provide room for the chargecooler hoses, a Citroen one was used!


The chargecooler location also required that the screen wash bottle was re-located, a smaller unit was mounted above the cooler.


The new turbo can just be seen nestling amongst the array of hoses!


The final modification was the deletion of the mechanical fan and fitment of a pair of fans each side of the radiator.
These are operated by the fan switch fitted into the thormostat housing, it can be seen in the first picture.

I know that I have said simmilar things before in this thread, but fitting the chargecooler has resulted in the most significant performance gain to date. Some of the additional performance was the new turbo, the CT12 was a bit worn, topping out at a measly 12psi, but I am in no doubt that the bulk of the additional torque has been gained from the very efficiant intake charge cooling.
A quick test with the coolant pump switched off shows how much difference there is.

TIM

[g-man]

nice one diesel ,chargecoolers could be the way to go

[ColinJack]

Well you have finally got there! Almost looks original too which is nice.
Interesting to see how it performs at North Weald next time out.

Nice one!

[limitedblack]

Please beat Matt

[dieselhead123]

I missed a run out at Weald with another lot, same date as the recent south coast meet.

Beat Matt?
It's Luke I'm after

TIM

[ColinJack]

What have you done about air filter?

[dieselhead123]

What have you done about air filter?

Cold air intake to install, drawing from below the o/s headlamp, filter box mounted above engine like on yours, (good idea that!).
Waiting on hose connectors, again!

TIM

[ColinJack]

What have you done about air filter?

Cold air intake to install, drawing from below the o/s headlamp, filter box mounted above engine like on yours, (good idea that!).
Waiting on hose connectors, again!

TIM

Must be getting pretty tight in there!

[dieselhead123]

Must be getting pretty tight in there!

Sure is

Air filter is not as nice as yours, just a plastic FreeBay jobbie, donated to a good cause by the Mad Machinist!

TIM

[Mad machinist]

Faux carbon dear boy, plastic indeed, huff