Intercooled Tourneo Mk5

[Luke]

interesting stuff tim .............. maybe now you'll be thinking that turbos too small

lets all club together and buy tim this http://www.ebay.co.uk/itm/K27-TURBO-TUR ... _655wt_932

[Guy88]

interesting stuff tim .............. maybe now you'll be thinking that turbos too small

lets all club together and buy tim this http://www.ebay.co.uk/itm/K27-TURBO-TUR ... _655wt_932

still a bit small

scania 16 ltr V8 turbo

[dieselhead123]

interesting stuff tim .............. maybe now you'll be thinking that turbos too small

lets all club together and buy tim this http://www.ebay.co.uk/itm/K27-TURBO-TUR ... _655wt_932

Funny you should say that Luke....
It happens to be in my 'watch list'
Not got the C12B on the van yet, I doubt that it will be on there for NW2012 as I have not yet quite completed the exhaust, I was hoping that the 'silencer' would turn up before the weekend, give me something to do, but it is going to be Wednesday now

Think I will be taking Guy's advice and winding up the stock unit as I only have 12-14psi at the manifold
I wonder how much it will produce?

Maybe I'll just remove the exhaust when I get to NW

[Luke]

i think you'll need to build a hybrid turbo for it in the end because if you fit one of the massive wagon turbos i dont think the Di wont move enough air in the turbine side to spin the compresser side fast enough to make the amount of boost you need

you need to start collecting scrap turbos to build some up lots of experimenting

[Guy88]

also run the wastegate from the manifold rather than the turbine

[dieselhead123]

also run the wastegate from the manifold rather than the turbine

That was the first mod mate, after the intercooler was fitted

[IgorVigor]

130ps injectors are tempting

As for stock turbo.....boring

K27 might be a little big.....but the marine 130 uses a K26 which is a big turbo....


As for silencer.....you dont need one

Straight pipe exhaust will be fairly quiet


A transit 2.5 should be able to provide plenty of flow for the exhaust turbine though.....

It will start spool a TD04L turbine at 2,000rpm, and 12psi around 2,500rpm....
So even on a stock engine/injection pump you get 1,500rpm full boost.

Governor mod of 3mm shim will give a nice 4,800rpm max rpm so 2,300rpm full boost.

A TD04L turbine is roughly equal to a 6cm^2 housing if I remember correctly.....
And its a 2.2 inch turbine I believe....

So with the governor mod (essential to provide enough midrange fuel in my opinion) big turbos (TD05HL, KKK K26/K27, Holsets) should be great

A holset hx30 tempts me
Or a big VNT (GT2560 or bigger)......

An efficient tubular manifold can lower the spool rpm of ANY turbo.....something to consider.....

[dieselhead123]

i think you'll need to build a hybrid turbo for it in the end because if you fit one of the massive wagon turbos i dont think the Di wont move enough air in the turbine side to spin the compresser side fast enough to make the amount of boost you need

you need to start collecting scrap turbos to build some up lots of experimenting

That had been a concern of mine, we will see what happens when the C12B is on there.

If I get any problems.....
..........I'll just stick a Supercharger up it's ass

[IgorVigor]

Thought this might interest some of you:

http://www.mermaid-marine.co.uk/documen ... erlin1.pdf


130ps model....

It doesn't say its a bosch pump, but if you look at the picture, it definitely looks like a bosch pump with a basic top (non HBA)

[dieselhead123]

Mmmmmm

It does look like a Bosch mate, with a cold start unit on the side!

That is the same 'base' unit that I am using, so the stories that you need to have the later Bosch pump to achieve maximum output are not strictly true!

The Stanadyne agent that supplied my injectors is also a Delphi agent, but not Bosch, perhaps that explained his ignorance regarding a Bosch pump option on the engine, he must have been referring to the earlier engines produced prior to the Bosch option being available on road engines.

I did search Bosch Esi, but found no reference to a Bosch pump fitted on Marine applications, so there is a 'hole' in Esi! Shame, because some details of the internals used in the pump may have helped us both with 'hybrid' pump builds

I will search Esi again using the engine codes etc in the link you posted, be nice to know what cam plate they used

Tim

[IgorVigor]

Well I have a 200tdi injection pump in pieces.....
So I have that camplate I can use for now (when I build a pump that is )

The power chart is interesting though.....

It shows power from 2,000rpm with no sharp increase.....suggesting the turbo is spooled at 2,000rpm :O

Which begs the question of how big the turbine is on the K26 marine turbo :S

[IgorVigor]

Any updates Dieselhead?

[dieselhead123]

Not had a good run in the bus since I fitted the 130's.

Busy tackling 'tin worm' in readiness for North Weald
And I have the rear seats to fit...

Not happy with an unladen weight of 2000kgs!

Still, at least the 'Sport Vans' will have a chance

[IgorVigor]

Not had a good run in the bus since I fitted the 130's.

Busy tackling 'tin worm' in readiness for North Weald
And I have the rear seats to fit...

Not happy with an unladen weight of 2000kgs!

Still, at least the 'Sport Vans' will have a chance

Haha

My swb only weighs 1750kg unladen (or something like that)
So mine is a sports transit

[dieselhead123]

Been in a battle with the tin worm over the last week, still got a bit more to do on the front o/s corner.

Normal stuff for an ageing Mk5, inner door step sill, door step, front out rigger, front wheel arch, front inner wheel arch and front wing.

I used parts from my supplier and was again happy with the quality. As normal for me, I changed the front wing but left the front extension piece, the part that houses the bonnet height stop, in place. This avoids the need to remove the headlamp, yet still allows sufficient access for my spot welder.

I used a n/s outer wheel arch as the basis for the o/s inner wheel arch repair, a small amount of shaping is required, but still a lot less work than starting from scratch. The genuine Ford front inner wheel arches are still available, nearly £100 with the vat, but I have decided to spend the money saved on a larger intercooler!

The new inner sill in place;


This was spotted to the underside of the door step well.

The new outer sill in place;

You can see the extent of the repair, the front part of the door step well and the front outrigger have both been replaced. Again, the spot welder eared it's keep;


New front wing in place;


Again the spot welder was employed, the front wing extension was left in place on the van, just the outer part of the wing being fitted.

I also fitted the rear set of seats, recently purchased from another Forum member and kindly collected by RobbieC.
These match the existing interior and fold away to provide a good amount of 'boot' space, great for all the shows
These seats are surprisingly heavy and together with all the tinwork, the van now has an ULW in excess of two tons!

I might just need that larger intercooler

Tim