intercooler. need to go big.

[missfixit70]

I'd love to hear from someone who has successfully fitted a beefier intercooler. Go on someone - have a go

Why not bypass it first to see if it is actually improving performance?

You reckon it's not then Mel?

[The Great Pretender]

Only one way to find out Kirsty, Doesn't look very efficient does it.

[mikeonb4c]

Only one way to find out Kirsty, Doesn't look very efficient does it.

Don't think Mr Mazda would like to hear you talking like that Mel

[The Great Pretender]

All my statements are scrutinised by my libel lawyer before posting.............

[Northern Bongolow]

im going to remove one at the weekend to service/inspect . may just be tempted to link up the air pipe minus cooler and give it a blast round the block and note the approx temps via mason settings,probably accurate enough for a test.

[mikeonb4c]

im going to remove one at the weekend to service/inspect . may just be tempted to link up the air pipe minus cooler and give it a blast round the block and note the approx temps via mason settings,probably accurate enough for a test.

That sounds like it could be really interesting - I'll watch this thread with interest

[tomheaney99]

any news yet? was an interesting thread to read

[Northern Bongolow]

sorry guys,i forgot id posted this,
removed the intercooler/aftercooler,cleeaned out the internals,which wasnt actually that bad,just wet with cooling oil vapours settling in the lowest point of the system,would have thought there may bequite a bit of gunk in there as the rest of the system is blathered in crud.
didnt do the bypass aftercooler test sorry didnt have time.so no real conclusions there.
just really trying to establish if the gung is getting in to the air system from the turbo or the rocker cover breather and running back to the aftercooler.
conclusion is not that satisfactory either,little bit getting in from the turbo,but most is from the rocker breather,will have to get to the bottom of this as it seams to affect quite a few bongos.maybe a nonfunctioning rocker breather valve,if fitted?? anyone know if there is a bottom end breather fitted,

[Simon Jones]

Ady - I've still not found any crankcase ventilation on the block itself. Also, there seems to be no valve in the rocker cover breather - it just goes straight back into the ducting from the turbo at the rear of the head.

[Northern Bongolow]

thanks for that simon,wast sure if there was a valve at the rocker end somewhere,is it a gauze disc or something?

if the rocker gases are not being pulled through the system in the normal good airflow,this gunk must mean that there is a leak in the vacum created in the air intake circuit???

could be worth checking all connections in the system,or even rubbed through pipes,what do you think.

[def_fid]

I am new to Bongo's but have been extracting reliable power out of landrover 2.5 tdi's.
Firstly, the EGR is an Exhaust Gas Recirculator- a very crude way of reducing emissions. It is doubtful if they have any beneficial effect whatsoever on an older engine. It is common practice in landrover circles to blank off the EGR, which will slightly reduce intake temperatures and very slightly increase turbo RPM. You will notice a detectable improvement in performance in a healthy engine.
High exhaust gas temperature (EGT) is what destroys cylinder heads/valves. Running a high fuel/air mix such as caused by worn injectors, overfuelling by messing about with fuel distribution pumps and crucially driving heavily laden vehicles up steep hills in a high gear will see exhaust gas rise above 730 degrees C, which destroys valves. Increasing charge air density by substantially increasing the intercooler efficiency does no harm to the engine, and will result in greater torque at lower revs, which improves fuel consumption. My 300tdi went from 26 to 29mpg, but with dramatically improved performance.
Increasing turbo boost pressure will give a hike in performance, but causes an exponential increase in EGT.If you want long engine life, do not exceed 15psi ( 1 Bar). Reducing back pressure in the exhaust will improve turbo efficiency and help with EGT control. ( Dump any catalysts in a Diesel system, fit a large bore exhaust, low back pressure silencer.
Make 100% sure the cooling system is working as it should. Supercooling additives help. Fit indestructible hoses and double clip with stainless jubillee clips (2 to each joint).

I also have an LPG injection system fitted which improved overall performance by 15%, but that cost over £700. Allisport will make intercoolers and high efficiency radiators.

Hope this helps someone

[mikeonb4c]

I am new to Bongo's but have been extracting reliable power out of landrover 2.5 tdi's.
Firstly, the EGR is an Exhaust Gas Recirculator- a very crude way of reducing emissions. It is doubtful if they have any beneficial effect whatsoever on an older engine. It is common practice in landrover circles to blank off the EGR, which will slightly reduce intake temperatures and very slightly increase turbo RPM. You will notice a detectable improvement in performance in a healthy engine.
High exhaust gas temperature (EGT) is what destroys cylinder heads/valves. Running a high fuel/air mix such as caused by worn injectors, overfuelling by messing about with fuel distribution pumps and crucially driving heavily laden vehicles up steep hills in a high gear will see exhaust gas rise above 730 degrees C, which destroys valves. Increasing charge air density by substantially increasing the intercooler efficiency does no harm to the engine, and will result in greater torque at lower revs, which improves fuel consumption. My 300tdi went from 26 to 29mpg, but with dramatically improved performance.
Increasing turbo boost pressure will give a hike in performance, but causes an exponential increase in EGT.If you want long engine life, do not exceed 15psi ( 1 Bar). Reducing back pressure in the exhaust will improve turbo efficiency and help with EGT control. ( Dump any catalysts in a Diesel system, fit a large bore exhaust, low back pressure silencer.
Make 100% sure the cooling system is working as it should. Supercooling additives help. Fit indestructible hoses and double clip with stainless jubillee clips (2 to each joint).

I also have an LPG injection system fitted which improved overall performance by 15%, but that cost over £700. Allisport will make intercoolers and high efficiency radiators.

Hope this helps someone

Interesting post (and welcome). We've had a big debate (about a year ago) about LPG injection on diesel Bongos, which started after I'd met a Landie owners who was getting great results from LPG injection + bigger intercooler on his Landie. One Bongo member on here has LPG injection (hembracho / Andy) and reckoned he got 45mpg on a run recently. I keep wondering if I might give it a go myself.

Any more info you have on who can fit it and what costs are, would be interesting.

[def_fid]

I am new to Bongo's but have been extracting reliable power out of landrover 2.5 tdi's.
Firstly, the EGR is an Exhaust Gas Recirculator- a very crude way of reducing emissions. It is doubtful if they have any beneficial effect whatsoever on an older engine. It is common practice in landrover circles to blank off the EGR, which will slightly reduce intake temperatures and very slightly increase turbo RPM. You will notice a detectable improvement in performance in a healthy engine.
High exhaust gas temperature (EGT) is what destroys cylinder heads/valves. Running a high fuel/air mix such as caused by worn injectors, overfuelling by messing about with fuel distribution pumps and crucially driving heavily laden vehicles up steep hills in a high gear will see exhaust gas rise above 730 degrees C, which destroys valves. Increasing charge air density by substantially increasing the intercooler efficiency does no harm to the engine, and will result in greater torque at lower revs, which improves fuel consumption. My 300tdi went from 26 to 29mpg, but with dramatically improved performance.
Increasing turbo boost pressure will give a hike in performance, but causes an exponential increase in EGT.If you want long engine life, do not exceed 15psi ( 1 Bar). Reducing back pressure in the exhaust will improve turbo efficiency and help with EGT control. ( Dump any catalysts in a Diesel system, fit a large bore exhaust, low back pressure silencer.
Make 100% sure the cooling system is working as it should. Supercooling additives help. Fit indestructible hoses and double clip with stainless jubillee clips (2 to each joint).

I also have an LPG injection system fitted which improved overall performance by 15%, but that cost over £700. Allisport will make intercoolers and high efficiency radiators.

Hope this helps someone

Interesting post (and welcome). We've had a big debate (about a year ago) about LPG injection on diesel Bongos, which started after I'd met a Landie owners who was getting great results from LPG injection + bigger intercooler on his Landie. One Bongo member on here has LPG injection (hembracho / Andy) and reckoned he got 45mpg on a run recently. I keep wondering if I might give it a go myself.

Any more info you have on who can fit it and what costs are, would be interesting.

Allisport nr Newent in Herefordshire/Gloucestershire, they also do big intercoolers and high efficiency radiators. My Defender 110 gets 35mpg on a run, pulls like a train. I've been running the system for 4 years now, no reliability problems. It uses turbo boost pressure to vary the gas input, which feeds straight into the inlet tract after the air filter. No gas below 4.5psi boost. The unit is from the USA and was easy to fit. I use a refillable automotive 30 litre tank. The makers say to use calor gas, but that isn't registered as road fuel, plus its more expensive than LPG, which works fine.

[mikeonb4c]

I am new to Bongo's but have been extracting reliable power out of landrover 2.5 tdi's.
Firstly, the EGR is an Exhaust Gas Recirculator- a very crude way of reducing emissions. It is doubtful if they have any beneficial effect whatsoever on an older engine. It is common practice in landrover circles to blank off the EGR, which will slightly reduce intake temperatures and very slightly increase turbo RPM. You will notice a detectable improvement in performance in a healthy engine.
High exhaust gas temperature (EGT) is what destroys cylinder heads/valves. Running a high fuel/air mix such as caused by worn injectors, overfuelling by messing about with fuel distribution pumps and crucially driving heavily laden vehicles up steep hills in a high gear will see exhaust gas rise above 730 degrees C, which destroys valves. Increasing charge air density by substantially increasing the intercooler efficiency does no harm to the engine, and will result in greater torque at lower revs, which improves fuel consumption. My 300tdi went from 26 to 29mpg, but with dramatically improved performance.
Increasing turbo boost pressure will give a hike in performance, but causes an exponential increase in EGT.If you want long engine life, do not exceed 15psi ( 1 Bar). Reducing back pressure in the exhaust will improve turbo efficiency and help with EGT control. ( Dump any catalysts in a Diesel system, fit a large bore exhaust, low back pressure silencer.
Make 100% sure the cooling system is working as it should. Supercooling additives help. Fit indestructible hoses and double clip with stainless jubillee clips (2 to each joint).

I also have an LPG injection system fitted which improved overall performance by 15%, but that cost over £700. Allisport will make intercoolers and high efficiency radiators.

Hope this helps someone

Interesting post (and welcome). We've had a big debate (about a year ago) about LPG injection on diesel Bongos, which started after I'd met a Landie owners who was getting great results from LPG injection + bigger intercooler on his Landie. One Bongo member on here has LPG injection (hembracho / Andy) and reckoned he got 45mpg on a run recently. I keep wondering if I might give it a go myself.

Any more info you have on who can fit it and what costs are, would be interesting.

Allisport nr Newent in Herefordshire/Gloucestershire, they also do big intercoolers and high efficiency radiators. My Defender 110 gets 35mpg on a run, pulls like a train. I've been running the system for 4 years now, no reliability problems. It uses turbo boost pressure to vary the gas input, which feeds straight into the inlet tract after the air filter. No gas below 4.5psi boost. The unit is from the USA and was easy to fit. I use a refillable automotive 30 litre tank. The makers say to use calor gas, but that isn't registered as road fuel, plus its more expensive than LPG, which works fine.

That's really useful and thanks for posting the info. Do you have a rough idea of costs for various bits of work?

[def_fid]

The Tank was about £300, the Gas unit about £400, but that was a few years ago. Secondhand LPG tanks are easy to get, but a bit big, so I used a 30 litre vertical portable ( but approved for vehicle installation)tank, with a remote filler. I've just bought a 97 Bongo TDi 4WD, with 63000 miles. looking forward to playing with it.