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diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6041

IRB Variable vane turbo fitting ...oh yes!!!!

So, after driving my Td5 110 for a while (had one previously to this as well) I fancied a

little engine upgrade.

I'd already fitted an Allisport intercooler, boost box, and flashed the ECU to 170bhp

(although it's quite a revvy tune, needs some of Ian's magic to make it a little more

drivable)

Got a 1.2:1 transfer box in it too, so drives very nicely, but once you come off boost,

there is next to no power, so it's rather "on" and "off", which isn't too fun.

After chatting with Ian, he ordered me a VGT turbo kit. It duly arrived so I popped up to

his place and grabbed it, stuffed a brown envelope full of used notes in his hands, and

hurried on back home to fit it.

It's dead easy, as the turbo's on Td5's are easyily accessable anyway, so one evening I

cracked on with it.

First job is to drain the oil, as part of the warranty you need to have fresh oil, so I got

the drain pan (I use an old jerrycan with the side cut out of it)

Here's where the first worry started... the oil was happily pouring out, then I heard a

metallic "clunk" as something metal fell out the sump and landed in the oil pan.

Fishing around, I found this:

Click image to enlarge

A valve collet.... oh dear.... I'll look into that later...

Next job, get the turbo out of the wrapping and assemble it.

Mine didn't have the exhaust elbow fitted, so just a quick job of putting a little exhaust

paste on the end of the casting and bolting it together.

Click image to enlarge

Click image to enlarge

Next job, remove the turbo heat shield. It's just 3 bolts to get it off:

Click image to enlarge

Click image to enlarge

The end bolt needs a small extension bar with a 13mm socket on it:

Click image to enlarge

And there she is in all her (boring standard) glory:

Click image to enlarge

Undo the pipes

Click image to enlarge

and then the 3 nuts on the downpipe, then the 3 nuts holding the turbo to the manifold, and

remove:

Click image to enlarge

Old Vs. New:

Click image to enlarge

Click image to enlarge

Now is the ideal time to change the filter, as it's easy to get to!

Tip: wrap a plastic bag around the filter, so when you undo it, you don't get covered in

oil.

Click image to enlarge

Click image to enlarge

Included in the kit is a new oil feed pipe, which needs changing.

Click image to enlarge

You need to remove the filter casting to get to the banjo bolt to change the pipe. It's

only three 10mm bolts to get it off. There's a gasket behind it too, but luckily mine was a

plastic type gasket (that, or the paper had just gone "hard") so i was able to re-use it.

Click image to enlarge

I also changed the centrifugal filter too whilst I was in there:

Click image to enlarge

After that, it's just a case of refitting the new turbo:

Click image to enlarge

Click image to enlarge

Everything bolts back up as normal. The top oil pipe needs a little jiggling to get it into

place. If it ever failed, i'd get a new one made up with smaller crimped bits on, as

they're about an inch long so drastically reduce the flexibility of the pipe.

the lower oil drain pipe could also do with a little "tweek". mine bolted up with me

bending it slightly, but I need to actually "bend" the pipe so it reduces the stress on the

2 small bolts that are holding it in place.

So, the result?

Well, It hasn't turned it into a fire breathing monster (although once I stuff some more

used notes into Ians hands and its got one of his tunes, it may well be) but its made the

vehicle much more drivable, It's just like driving a modern day TD, you have torque and

"pulling away" ease from low revs straight away.

Hills that I used to have to change down a gear to get the engine up on boost, I now can

just cruise up by putting my foot down.

So it's really transformed the driveability of it.

Happy? Oh yes!!!!!

The collet turned out to be a "spare"... I took the rocker cover off, and all 20 other ones were present and correct, so it must have been an extra one dropped in during manufacture

5th Nov 2009 2:52pm

walfy

Member Since: 29 Aug 2007
Location: Frome
Posts: 2642

Nice!!!!

.

Will have to get out laning now to see if it works offroad as well. Give me a shout soon

110 D250 SE HT
110 USW SOLD
RRE HSE Dynamic Gone, wife killed it
VOLVO XC60 R Dynamic with some toys

Polaris RZR 900XP SOLD

5th Nov 2009 8:14pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 7706

2011 Defender 110 Puma 2.4 USW Stornoway Grey

cool.

out of interest i noted someone mentioned that for VVT they needed some back pressure and ran best with a cat and mid box fitted to provide this pressure. my TGV runs without any boxes in it and seems good to me - i dare say yours is one box? or straight through. just wondering if it would be better if not straight through. is this something you looked into?

You out this weekend in Wales with us? Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop

5th Nov 2009 9:11pm

TJ101

Member Since: 30 May 2007
Location: Taunton Somerset
Posts: 3747

2015 Defender 110 Puma 2.2 XS CSW Montalcino Red

Good post

Know what you mean about the power being a tad high,, Have a 90 TD5 with a JE stage 2 tune, exh , cooler disco transfer box etc,, and that really needs something doing about it,, !!!
Will have to wait until the Puma done !!! California F1, 75th 110 "Kermit", 50th Ann V8, 90 V8 Hybrid, 55 Series 1

Main Brian James Trailer Dealer for South West UK

5th Nov 2009 9:53pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6041

I've got the big middle silencer, and straight out pipe from that to the back, it seems to spin up well.

Been out lanng today Mark. goes well, even on the general TR's!!

5th Nov 2009 10:00pm

walfy

Member Since: 29 Aug 2007
Location: Frome
Posts: 2642

Will be a while till I'm out again. Bonfire tomorrow, clean up Sat. Rememberance Sun. Then work Mon, Tues, offroading on Wed allday, Wed night to Kent. Thur AM to Germany, return Mon PM. So will be avail that week if you fancy a trot out then? 110 D250 SE HT
110 USW SOLD
RRE HSE Dynamic Gone, wife killed it
VOLVO XC60 R Dynamic with some toys

Polaris RZR 900XP SOLD

5th Nov 2009 10:51pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6041

Yeah, i'll be up for that mate.

did some lanes this afternoon, just had a job in, so literally got in about 5 minutes ago (still, at least the pub can now carry on their quiz night as the jukebox is now working

)

5th Nov 2009 10:52pm

Steve B

Member Since: 22 May 2009
Location: Warwickshire
Posts: 586

Good information, sounds like it does a good job and its a tidy installation.

So its just all bolt on? how the variable vane work is it on turbo speed/ pressure or electricery?

How much does all this retail for? kind of tempted myself

Thanks Diesel Jim

5th Nov 2009 10:55pm

diesel_jim

Member Since: 13 Oct 2008
Location: hiding
Posts: 6041

Yup, bolt straight on. the only thing to tweek is the oil drain pipe (although i managed to get mine to fit, but it's got a little weep on it) so remove the pipe and "kink" it by a few degrees, that's all.

You get a new top pipe to fit (Which just comes off with the banjo bolt) and then it's all plain sailiing. no manifold to change, no exhaust down pipe, nada.

Variable vane is operated the same way as the original waste gate, from that small rubber pipe which operates a "waste gate actuator", but in this case it's a "vane actuator". looks the same though, but connects up differently.

Price is only

a couple of hundred more than a brand new standard turbo, so not that bad really.

5th Nov 2009 11:02pm

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