Isuzu Engine Astra MK3

[Vauxdan10]

The one i hacked up was the original manifold with the secondary airfilter on top.
(looks better, and as a bonus: i can swap injectors without removing the intake manifold)

The newer type manifold can not really be hacked / modified, you can however use it to
fit an intercooler, like so:

Hi mate can u please tell me how u fitted that intercooler?I've got 1 for my 1.7tds astra,my inlet has 2 ends on it,on the left of it is the air filter and on the right is a pipe that comes from the turbo with a little tube half way along to the rocker cover,I've noticed in ur pic ur air filter Is on the right and 1 of the pipes from the intercooler is linked up in it's place,so were is ur airfilter linked up 2 now and were does the right tube off the intercooler go?is it straight to the turbo?and y hasn't ur inlet manifold got an inlet hole on the right of it?sorry for all the questions,just want a clearer idea of how to fit it before I attemp it! Thanks,Dan

[DutchNovaDiesel]

First: It's not my car (it was the Count's: Vauxhall Corsa 1.7 td van (yes its a 1.7 td))

The filter goes straight onto the turbo, makes it whistle when you boot it

The inlet manifold is from a N/A Isuzu(and was Polished), to make it work you need to drill 1 hole to add a pipe (for the connection to the injectionpump) and block the breather hole on the manifold.
You can add a filter to the breather connection on the rocker cover, or just add some hose and point it to the ground

And yes, the intercooler connection on the (UK)passenger side comes straight from the turbo.

Here's my (previous) setup:

[Vauxdan10]

Probably a stupid question but what is an 'n/a' inlet and were can I get 1 from?

[Vauxdan10]

Probably a stupid question but what is an 'n/a' inlet and were can I get 1 from?

And also if I was to keep my existing manifold how would I go about setting it up,I know most of it,left pipe of ic to left of manifold,right pipe of ic to turbo,cone filter straight off side of turbo,then I presuming I can block up the 2 holes on the right side of the manifold???but then what about that little bit of pipe that links the rocker cover to the pipe joining onto the right side of the manifold?what can I do with that?

[DutchNovaDiesel]

N/A = naturally aspirated

Here's the difference between the two manifolds:

The turbo manifold has a plate between the top and bottom half, the N/A manifold doesn't.

If you want to keep your current manifold just add the intercooler and connect it to the same pipes.
(it's just easier to connect a FMIC to a N/A manifold then to a turbo manifold)

The "little bit of pipe" = breather connection (see my previous post)

[davidmckinney]

what size of intercooler did you used..?

[Prilo]

Some thing is wrong with my boostcontroller. I bought a brand new bleed valve, from an othorised dealer here.
There is the full pacage:



The T-peace has an arrow on it, that points toward the actuator. And I know it sounds strange, but there's one way valve in to it. It is adjusted to let the air trough, at ~1 Bar.
That means, I can not adjust the bleed valve under 1 Bar setup (0.9 for example).

I put the T-peace on the actuator's boost hose, and I connected the bleed valve to the T-piece.
This is the bleed valve, connected:



So, I went for a ride. The boost goes up to 1 Bar, where the safety blow-off valve reacts, and the pressure drops immediately down to 0.5 Bar. This makes the inlet system, loose a lots of air, very quick. It happens on a too low revs, what makes the gear drop really bad and it is actually much worse than with the original set up.

I blame it on the T-piece, whose valve is adjusted to ~1 Bar, and becouse of it, the safety blow-off valve reacts, before the bleed valve.

So I bought a regullar freeflow T-piece, with no valve in to it.
There it is, on spot:



I went out for another test-drive. This time, there was no difference from the original boost set-up. The waste gate opens at 0.8 Bar, like it was in the original condition. I've turned (adjusted) the bleed valve many times, from the low end point to the top end point, but no change at all. The boost limit, remains at 0.8 Bar, no matter what.

Can please, some one tell me, what am I doing wrong?

Thank you.

[r1chy]

hi there,, think there may be a "over boost blow off safty valve" on the turbo

[Prilo]

Overboost blow-off safety valve, has been isolated successfuly

http://prilo.snimka.bg/tuning/tc4ee1.495950.20082289

I'm runing at 1.10-1.15 Bar now. The problem was also the T-piece. Not only the safety valve.
With the safety valve isolated, the turbo use to go easy up to 1.4-1.5 Bar and even more. I've got frightened, to push it to the max limit. I cut off the spring inside the T-piece and this is how the boost level went down to ~1 Bar.

[Prilo]

And this is my way for tuning the intake system, with the standard intercooler.

[saxiaq]

hello sir , this is from malta.. the island of diesel freeks lol, here in malta do much more than that, we fit big turbo's on them such as kkk turbos, garrett t25's , t28's , t3's and even a t4 !
for example mine is with a ball bearing t4 turbonetics turbo.. the gtk series..
.. ok such mods have be done.. but not big ones!
the three thing that you mainly should have are, a good diesel pump , a well sized intercooler and a good turbo.. to do some real boost 35 psi ++ even 40psi with full boost
here in malta.. the avrage of a semi tuned engine is 14.7 sec @ 1/4 mile.. with a miserable nissan t28 turbo blehh ****ing not good, i would recommend a garrett t3 turbo (like the one of a cosworth ) and youll do 14.5's easy with no nitrous or any internal engine mods.. any questions just ask .. ahh btw i was just to forget.. ahh just was to forget.. last 1/4 mile that i gone.. last week.. my friend went far across the line than a tuned sierra coswort 2wd .. the cosworth is near the 400 hp and nothing to do with that mad isuzu hehe these thing that i mentioned seems to be all lies, but no !! just the true real story cu guys

Aw siehbi andek xi msn jew xi haga? isma jien andi 1.5Td isuzu 4EC1 u ed nithajjar nitfala manifold u turbo ta trooper tal 3.1. Xtahseb man?

[saxiaq]

N/A = naturally aspirated

Here's the difference between the two manifolds:

The turbo manifold has a plate between the top and bottom half, the N/A manifold doesn't.

If you want to keep your current manifold just add the intercooler and connect it to the same pipes.
(it's just easier to connect a FMIC to a N/A manifold then to a turbo manifold)

The "little bit of pipe" = breather connection (see my previous post)

I have a turbo inlet monifold but is damaged ( cause of a crash ) I cannot find one here in malta. I found a non turbo inlet manifold but. I have noticed that pipe labeled "from intercooler outlet" on your diagram is closed. By opening the hole and connecting the pipes to it should there be any problems? as in your diagram you displayed a seperator

[saxiaq]

I have a turbo inlet monifold but is damaged ( cause of a crash ) I cannot find one here in malta. I found a non turbo inlet manifold but. I have noticed that pipe labeled "from intercooler outlet" on your diagram is closed. By opening the hole and connecting the pipes to it should there be any problems? as in your diagram you displayed a seperator

Adding up to what I wrote before I designed a diagram and waiting for response. Is the layout I designed like the blue corsa over here? I intend to use an N/A manifold as mine is damaged
[IMG]file:///C:/Users/Stefan/Documents/corsab1.5TDintake.png[/IMG]