Intercooled Tourneo Mk5

[ColinJack]

Wow!

Nice job - hope it performs as well!!

[AlanN]

Could Andy's record fall this weekend then

[dieselhead123]

Could Andy's record fall this weekend then

Stranger things have happened

I'll get some more pics up in the morning, but today it was running

There are alas a couple of problems

There is an oil leak on the feed return flange of the turbo, now I know that I cracked the case when I spun the exhaust end
I did weld it up but sealant will not suffice even with the new gasket so perhaps the face is too distorted or the case has a crack between oil feed and return.

But the major problem seems to be the limited boost available, 12psi is just not good enough! Looks like it will be treated to a new one as there does seem to be more play in the shaft than when the turbo was on the bench!

On a plus side, the exhaust does sound sweet and quiet despite being a straight through three inch bore, we all expected a bit more noise!

Performance is ok though, 5000rpm being achievable through the gears.

Looks like we will all be working through the night to meet the Weald deadline

TIM

[dieselhead123]

A fresh start today has revealed an oil slick under the van, safe to say the turbo is no good
Looks like I will be ordering a bew core Monday

But I did find the other pics of the install, here we go;

The 'silencer' and the side exit;


In the long term I would like to see the exhaust exit via a tube welded between the inner and outer sills, but I think that will have to wait until after Weald!

Some other pictures taken of the turbo installed on the engine;




At least the water connections did not leak!

TIM

[dieselhead123]

Alas, still no turbo, but.....

The chargecooler rad has been fitted, managed to get this behind the standard grille;


Just a small amount of trimming to the rear of the grill.

Here we see the grille in place;


Very Stealth

TIM

[limitedblack]

Did you dyno the engine before modding ? Over sizing exhausts don't give low down torque, only high bhp, would be interesting to see how the power curve would change from this. 2 1/2 or 2 3/4 should be about right for 150-200 bhp.

Just interested to know what you are basing your sizing on, or is it a try and see old school approach

[dieselhead123]

It will be interesting to get it on a Dyno once the latest round of mods are completed but the only standard figures we will have to compare to will be the factory claims.

The stock exhaust was about 2.5 inch, although heavily silenced, but I was getting excessive, (700 degree C), EGT readings at the end of one standing quarter run so I needed to reduce the 'back log' in the exhaust system and 3 inch parts were quite cost effective and easily available

I suppose it was a bit 'suck it and see' but as I intend to run up to 30psi of boost, that's a lot of gas to get rid of!

TIM

[limitedblack]

Love it, proper tuning

[ColinJack]

Love it, proper tuning

You know Tim's motto ...

"Smoke means too little air NOT too much diesel!"

[limitedblack]

You would think diesel tuning to be really simple, better atomisation with higher fuel pressures = less smoke more poke, more air = less smoke more poke, and more diesel = more poke more smoke

Put a plate over your floor where the flywheel sits, seen a few "lightened" ones let go big time.

[limitedblack]

Progress report ???

[dieselhead123]

Still no Turbo

Just how long does it take to 'file out' a compressor housing anyway?

Even the chargecooler install has 'stalled' as some of the pipe fittings were 'lost' in the post!

I have seen some talk in another thread of a possible second quarter mile meet, be good to get an 'official' time in before Mania, counting telegraph poles while looking at a stop watch is not quite the same

TIM

[limitedblack]

British industry slowing you down again

[dieselhead123]

British industry slowing you down again

Could be mate, or maybe the posty has got sunburnt knees

TIM

[limitedblack]

Saw Matt and Guy (88) today, looks like a three horse race for that Di trophy