Graham Jackson's TDI 110 Defender

[R_Lefebvre]

Graham, the kit looks good, and I agree that careful selection of mods shouldn't decrease durability, and generally the kit looks good. Except... I would throw away all those worm screw clamps and replace them with T-bolt band clamps. T-bolt band clamps are vastly superior in clamping force and durability.

http://www.atpturbo.com/mm5/merchan...tp&Product_Code=CLC-CLA-002&Category_Code=CLA

Also, some of those pipes (or all of them) appear not to have been bead rolled. They really need to be. Especially the boost side. You'll risk getting a blow-off. I've suffered them myself, and now ALL my pipes are bead rolled. An alternative is simply to weld a bead onto the end of the pipes.

And that black piece of silicone hose, not sure on the quality, looks like it was cut with a chain saw. I really prefer hump connectors wherever possible. They act like a bellows, and allow the hose to accomodate any movement without strain.

http://www.atpturbo.com/mm5/merchan...roduct_Code=ATP-SIL-048&Category_Code=SIL-HMP

 

[Maryland 110]

Graham,
I had spoken to Keith about his right after he installed it and he was raving.
Your pictures bring some of what he was telling me to light. Nice write up. I can totally relate to how a loaded 300 stumbles off the line with a cloud of soot.
Whats the red canister behind the head on the bulkhead ? Curiosity is killing the cat.
Thanks
Doug

 

[overlander]

Graham,
I had spoken to Keith about his right after he installed it and he was raving.
Your pictures bring some of what he was telling me to light. Nice write up. I can totally relate to how a loaded 300 stumbles off the line with a cloud of soot.
Whats the red canister behind the head on the bulkhead ? Curiosity is killing the cat.
Thanks
Doug

The red cannister is a helton heat exchanger! Mine is on order so that's how I know (and he pictured it in his water system writeup).

Graham,
Those parts pics help me out a bunch with understanding my 2.8. I have an uninstalled EGT gauge, but I've resisted removing my turbo for the probe install due to lack of understanding of the components, but also because I have no gasket spares. Is there a gasket that mates between the turbo and the exhaust manifold piece? If I new I could remove the turbo and not be stuck with a broken gasket that would deadline my vehicle, I'd do it sooner than later. if I have to order a gasket from overseas, that will drag things out for me.

 

[R_Lefebvre]

You need to take a close look at your turbo inlet. If it's a standard exhaust turbine casting, you should be able to get a standard gasket in the US.

http://www.atpturbo.com/mm5/merchant.mvc?Screen=CTGY&Store_Code=tp&Category_Code=GSK

Graham's does not look standard to me. It has 3 mounting bolts, normally they have 4.

http://www.turbobygarrett.com/turbobygarrett/catelog/Turbochargers/GT22/GT2252_452187_6.htm

Maybe that is a VW gasket?

http://www.atpturbo.com/mm5/merchan...tp&Product_Code=ATP-VVW-159&Category_Code=GSK

 

[Maryland 110]

The red cannister is a helton heat exchanger! Mine is on order so that's how I know (and he pictured it in his water system writeup).

.

Mark can you pm or post a link to his water system write up ? Did you decide to come to MAR ? I'd like to see some of the neat modifications you have made like the onboard computer built into the cubby box etc.

 

[overlander]

Mark can you pm or post a link to his water system write up ? Did you decide to come to MAR ? I'd like to see some of the neat modifications you have made like the onboard computer built into the cubby box etc.

I'm going to MAR! Registered over the weekend. Stop on by! I'll be in the family section (wherever that is).

Graham talked about his water system design in Winter 08 issue. I'm doing something similiar, and my phase I water system will hopefully be installed for MAR. Phase II includes filtration like graham has, but the larger double filter that is good for untreated water filtration at 2GPH per minute (his restricts to .5gpm). If I'm going to bring my family along with me, they are going to want treated water for showers. We can always drive to a water source as needed, and ration when there is none.

 

[gjackson]

Is there a gasket that mates between the turbo and the exhaust manifold piece? If I new I could remove the turbo and not be stuck with a broken gasket that would deadline my vehicle, I'd do it sooner than later. if I have to order a gasket from overseas, that will drag things out for me.

There is no gasket between the exhaust manifold and the turbo. It's just metal on metal but both surfaces have been smoothed. No leaks there on mine or Keiths.

cheers

 

[overlander]

Thanks Graham. I guess that means there's no reason for me not to pull the turbo for that probe install. You always have the most useful information!

 

[gjackson]

Also, some of those pipes (or all of them) appear not to have been bead rolled.

And that black piece of silicone hose, not sure on the quality, looks like it was cut with a chain saw.

The boost side is bead rolled. There is only one tube in the kit for the boost side from the turbo to the intercooler. (First pic, silver tube on right hand side). The intercooler back to the intake still uses the stock hose.

The black connector tube is a bit oversize for the job. I may investigate something a little better.

cheers

 

[gjackson]

Thanks Graham. I guess that means there's no reason for me not to pull the turbo for that probe install. You always have the most useful information!

No worries, glad to help.

On the cost side, I know there were comments in the D90 thread about the relative expense of this kit. The way I look at it, it's a great compromise between the cost of a new stock turbo (at ~$1500) and the cost of a 2.8 (at ~$7500). It's not cheap, but it improves the drivability of the motor, and, I would argue, lessens the stress on the motor as you have to use a lot less skinny pedal to do the same job.

Just my 2c. I'll report on fuel economy at the end of the week.

cheers

 

[overlander]

It will be interesting to compare economy of a 300tdi with the variable turbo to a 2.8.

 

[ersatzknarf]

Perhaps you might consider to add the EGT probe downstream of the turbo... That's what we did on my 2.8 TGV.

 

[gjackson]

Perhaps you might consider to add the EGT probe downstream of the turbo... That's what we did on my 2.8 TGV.

Keith added a bung post turbo to add an EGT. Have one, but it is currently affixed to the RRC manifold and shows no desire to come free . . .

cheers

 

[overlander]

Perhaps you might consider to add the EGT probe downstream of the turbo... That's what we did on my 2.8 TGV.

How about a pic of where you put it? From what I understand, post turbo will read a few hundred less than true.

Sorry for the hijack Graham. I owe you a beer someday. Actually, I owe you a few.

 

[gjackson]

No worries. Generally post turbo you will be looking at approx 300° less than pre. Try to keep the EGT pre turbo less than 1000, so less than 700 post. Or something like that.

I'm always up for a good beer . . . :sombrero: I'll post up a pic asap. Leaving early am so maybe not until the weekend.

cheers