850 tdi upgrade project

[doingitsideways]

Mine desperately needs new oil, belts too.

Any chance you could PM me some tips or links to any how-tos there may be on doing the belts, Martin?

I peeled the cam belt cover back the other day and it's looking a bit grim tbh, a bit of oil too, so think the cam seal may have gone

If I manage to get it done in time, I may have to take it to Shakey and go for the slowest time on the VPC leader board!! Lol

Oh, did you ever sell that Ronbox you offered me a while back?

[martin_r_smith]

I did sell it mate.

Not sure on how to's tbh, but it's not difficult. Hardest part is undoing the crank bolt she is a mighty tight beast, and then having the tool to do the thing up tight enough again afterwards!

Pump belt is real easy, we could do that at shakey and then I'll time it up for you too.

I would have given mine a thrash up the strip but I'll still be settling in the new gaskets then, but next year she's having it!

[940TD]

Originally Posted by doingitsideways

Mine desperately needs new oil, belts too.

Any chance you could PM me some tips or links to any how-tos there may be on doing the belts, Martin?

I can send you a PDF and some links if you PM me your email address.

It's not as difficult as some people make out, it's the first cambelt I've done on my own and it's still there 5k later...

[martin_r_smith]

IT'S ALIVE!!!!!!!

The beast lives on, watch out polar bears ;-)

[B00TS]

Glad to hear it's ok...

[martin_r_smith]

Originally Posted by B00TS

Glad to hear it's ok...

it is certainly a relief!

I've put a few miles on it now and have total confidence in it again, Knowing that i have the best possible quality gasket now fitted. The 16 row setrab oil cooler is doing its job and temps are all good. Interestingly now though, if i drive it hard i can get the temp gauge up to normal 3 o'clock position but if i then slow down and drive steady i can get the gauge to drop down to 4 o'clock position.Looking on vol fcr this is only a difference of 91 and 87 degrees but it shows that the cooling systems, oil and water, are working extremely effectively. The fuel cooler i added a while ago is also doing a great job keeping the temps below 35 degrees even if i've got less than quarter of a tank where it previously would reach 60+ degrees.

Overall the car is running better than ever, it even sounds quieter and smoother the wife actually noticed too! So this now means that I may be in a position to push things a little further power wise as i feel i have done everything i can to improve reliability. The hunt shall now start for a better suited turbo,the 16T has done great up to now but it has run out of steam over 240bhp. I am going to try and find a Holset he221w as they have been proven on this engine to 300bhp, They are however fairly difficult to come by in this country so it may take a little while.

Injectors nozzle size will also be increased as I have currently maxed my 0.240 nozzles. I'm not sure which size to go to yet but at least 0.260's. Mapping is again a problem but i may have solved this problem,time shall tell.

Speaking of mapping, my plan is to have the MAF mapped out and run purely on MAP based smoke limitation. The Bosch mechanical flapper style maf is a massive restriction and is seriously hampering top end performance. It will also be better in the long run as good working mafs are getting harder to come by.

Other plans are just to keep tidying it up, Emma keeps nagging me about getting the bonnet sprayed so that is first on the agenda really as it lest the whole car down. A wheel refurb is also on the cards as the comets are starting to look a little ropey.

I'll upload some pics of the work later..

[martin_r_smith]

Purchased a bigger better turbo today! Let the quest for more power commence once more hahaha

[martin_r_smith]

I have been busy gathering parts so thought you might like a few pics.











All 3" pipework for inlet, with the anti-surge housing she'll sound like a jet on spool up! Also have a 3" GWE downpipe (thanks Soulboy) but that's at the garage being modified to fit. The turbo is a holset HE221W, capable of 39lb/min flow (approx 390bhp on a petrol, 280-300bhp on a diesel) and very fast spool up. I won't be using the holset exhaust housing but the angled housing off my 16t, happily holset used a mitsubishi chra on these so it fits perfect! Quick remap for more fuel and timing then dyno to see where we are. I suspect I will run out of fuel at 250 ish so I'll have to fit larger nozzles. Then it's a case of upping fuel and boost until the smoke is too much then backing off a bit, which should result in ~280bhp with torque limited to 550-600nm

[dieselderv]

Envy envy envy it's going to be a beast it's a beast now don't forget the pics as it all comes together good luck

[vololic3]

Hi as you can see Im new to this forum, and computers- just old fasioned.Anyway I started a 850tdi project and purchased 240 hi flow nozzles, but have now come across a problem.I what to use a bigger turbo and build exhaust manifold, but cant find a tuner who will allow home build items,they want you to buy their £900 one.Where did you go to tune your T16 turbo?