Sorry meant for the intercooler T:

 

2.4D Turbo 6 pot

 

Original pipework had too many joints and too much silicone

the Original pipework here - messy

the intercooler has been flipped so the inlet are at the top now.

New intercooler pipework fitted , i did want to change it all to solid alloy but the pipe bender just creased the pipe as it was too thin in the walls.

don't think you can see on this photo but the pipework from the Turbo runs at low level just above the gearbox

Turbo inlet hose and Turbo outlet below

 

ok took the Van for a full run out to work and back since doing the boost pipes and winding the fuel up

its pulling 1.2bar easily and the engines is running alot smoother since increasing the fuel , slight smoke off boost in the dark but ok in day light .

Runs so smooth now @ 70 mph and pulls to 90mph like a hot hatch

must be pushing out 150bhp minimum now. I:

 

Hi Rich, not spoken for ages mate.
Did you manage to sort the boost pin ? If so is it time for another run yet ?

Cheers.

Ron.

 

Sounds great you must be well happy. next year I will get a spare pump that I have modded should help mine. Back on the rollers this Saturday well interested to see what it is putting out now

 

Great stuff keep us posted and get some video on the rollers T:

 

Hi Guys,

T: I have just upped my boost from .6/.7 Bar to 1.0 mucho impressed with the results

 

i have had a good end to the week my van has made it to the front cover of issue 7 of vw bus t4 t5. been back on the rollers and well happy with the results since it was last done its been back on the same rollers and opperated buy the same guy the changes have been

adjusted the pump timing
been using diesel rhino
full stanless exahuast fromm pp tuning
new boost controller (the cheep rubish from ebay did nothing and the boost just keept climing)

the graph shows the time it was run before in orange 97.2 bhp 172 pound foot torque and uncontrolable boost
then in black when i got there today 113.6bhp 180 pound foot torque and 0.8 bar boost
then in red after i adjusted it on the rollers bit more fuel and more boost
127.2 bhp 204 pund foot torque and 0.9 bar boost A:A:

so you can say i am well happy

 

Great results Mole T:

well done

 

happy days then mole

 

Mine was not so good but I seem to have a problem with the turbo or something as it didn't pick up very well thus low bhp
Least it's given me a base to start from so watch this space
85.9 bhp/140 torque
0.7 bar

 

As you say good start, almost 11 over a new standard motor.
Have you increased your fueling?

 

gusto we all start somewhere,and then when we get there its good to look back I:

 

Yes only a little but the problem it the acuator thing needs opening and to put it blunt I have a c**p boost adjuster IDE do better using welding rods in a T peace as it will be better lol

 

Welding tips not rods as the tips have a hole in them

 

I've watched this thread for a long time but just can't pluck up the courage to convertI: my 2.4d as now got 140k on the clock,(is it to old to convert?) I'm the second owner (father in law was the firstT I've had it serviced regularly, recently had s/s side exit exhaust of pp tuning and I'm now using rhino diesel which leads me to my question! Since using the rhino I've been recording my mpg, I'm only getting 30 mpg is this about right? If not what should be my next step? Just had cam belt change, second belt, water pump and filters change!I:

 

Go for the conversion you won't regret it mine has over 180000 on it and gusto is over200000. Must say I don't really keep track of miles per gallon but the smiles per miles are great 2 T5s tried it on today on the motorway and I blew them both away

 

Mine has done 240k miles so sure it's the highest lol runs fine I think

 

Have you replaced/reconditioned much then or is it all standard?

 

Mole they had broken down

 

In tears as I went off in the distance

 

No tears just saving some fuel I hot there and back at that driving and used less than 1/4 by lots

 

No egt don't think ill need one as its not going to hear up
Enough to worry about , but what do I know lol

 

Why do you think it was so slow at boosting , as I have noticed it when driving mine and moles but just thought it was the van in general ?

 

Ok well from start to finish about 7 hours but I had a pig job getting the oil filter of and then had to change the oil filter housing/cooler but it realy is as easy as undoing about 16 bolts , change the dipstick and conect the oil feed/return then put new manifolds on and do up 16 bolts well 8 nuts and 8 Allen key bolts or maybe less , then conect the air filter and run a pipe from inlet manifold to turbo . Job done
Then after time and when ur ready u can add a boost adjuster and intercooler but its not needed if u don't want big power so just need boost gauge and of u go

Easy as that lol
£200 for manifolds turbo and oil cooler thing
Then boost gauge £12
And a 3 inch to 2 inch silicon bend £20
And I drove it to my meet the next day and loved it

Sorry forgot the gaskets and little bits but there not expensive

 

It's getting more appealingI: cheers for the infoT: if it also helps mpg it's shopping time

 

My exaust bolts are lose so I may time my self taking it all of and on again and record it so it shows its really not that hard

 

mole - 129 bhp!!! congratulations, bet your well chuffedA:

i have a spare genuine vw oil feed pipe with 16mm banjo bolts and copper washers if anybody needs one for their conversion. Used condition but perfectly servicable £15

 

Hey guys, just on with this conversion on my T4 coachbuilt, this is the story so far:

I need to get a 22mm hose for the breather but not sure what to do for the intake to turbo pipe, using the AAB inlet stub but can't seem to find a 70mm to 51mm u bend hose, suppose i could make another inlet using a smaller diameter tube, but i would rather just get 1 silicon hose that fits.
I've also got the standard ACV inlet with the EGR blanked off but that looks a bigger plumbing job round the engine so i don't really want to use that.

Any idea's or advice about a good shop selling silicon hose's?

 

Looking good so far you will get all the silicone hose and bends on ebay try mr silicone that's where I got some of mine from I think you need a 135 degree bend from memory

 

As Mole says Mr Silcone or AP Motorsport (its the same company on ebay ) just round corner from me T:

They do everything you need hose & clamps

 

remember that you buy hose on it's internal diameter and clamps on external diameter.

guess how I know this.......I: