Isuzu turbo diesel tuning guide

[KristofHA]

Thanks for the information.
Maybe i install a oil cooler, if i have the room.
Today i'm installing the new intercooler ( i wil post some pics today or tomorrow)
not mutch room in a corsa b.
if have a little solution for my heating problem, when the engine gets to hot, i turn on the interieur heating. Then the engine temp stays about 97°C.
I hope the intercooler will also help in cooling the engine. I'm not shure, because it's in front of the radiator, so that one will get less ( and hotter ) air flow.

[KristofHA]

I installed my new intercooler, bought it on ebay.
Pics found here:

http://www.cardomain.com/member_page...47_19_full.jpg

Making room

http://www.cardomain.com/member_page...47_20_full.jpg
connecting the intercooler
http://www.cardomain.com/member_page...47_21_full.jpg


Final, mounted the bumper without cutting in the bumper.
http://www.cardomain.com/member_page...47_22_full.jpg

another question,

i want to activate the fan with a switch when i'm driving.
i noticed that there are 3 wires on the fan.

Does enyone now witch wire to use? Where do i need to put 12V to start the fan?

thanks!

[Davcohen]

Wow quite a nice install there, have you tested out if it makes any difference

[KristofHA]

No, i didn't test it yet, tomorrow i will test it and see if it helps cooling down everyting.
The intercooler is al little "over kill", but it was the cheapist new one i found.
It fit's great, don't have to cut in the bumper, only underneat the headlight ( see pic ).
Piping was also a little bit difficult because the output and input of the intercooler was 60 mm, the input to the engine was 40 mm, and the output of the turbo was about 38mm.
I painted the intercooler black, so its "low profile"

[DutchNovaDiesel]

Nice work !

As for the cooling fan, have a look here:
How to wire a fan override switch

[KristofHA]

Thanks DutchNovaDiesel,

First tests seem good. Today ( outsite temp 13-14°C dis morning) the engine temp doesn't goes above 95°C when driving 140-150 km/h at 4000RPM.
Later dis day when i drive home i test it on normal outsite temp.
To be shure i'm going to connect a switch to the fan ( thanks for the link ).

[KristofHA]

Yesterday tested at normal outsite temp (24°C ).
Engine temp goes again to high when driving 4000rpm /145 km/h.
So i think there is only a little improvel in cooling.
Yesterday i make some holes in the bumpers ( where the plate normal comes )
Hope to get more airflow and better cooling.
Also connected the fan. I had to put ground to the red/white wire to activate the fan.
Didn't yet put the switch in the dasboard. So didn't test cooling with the fan.

[Davcohen]

any noticeable difference in the way the engine pulls?

[KristofHA]

Hello,

I didn't change anything other. ( i didn't yet install a bleed valve, are give more fuel).
But i think i feel that it had more turbo lag.
The turbo don't kick in so explosive as before. But when i driving and check the hose to the engine, then its nice cool. So cooling of the aire is now verry good.

[Davcohen]

i would add an additional cold air feed from the lower part of the front bumper or even very the wing to get more air in there, although once you up the boost you will notice a massive difference in performance

[KristofHA]

Hello,

Cooling is almost under controll. I made some holes at front in the bumper so the radiator gets more air flow.
http://www.cardomain.com/member_page...47_23_full.jpg
http://www.cardomain.com/member_page...47_24_full.jpg

Now when i driving for serveral minutes 4000 rpm at 0,6-0,7 bar, then the temp goes slowly to 98°C. I hope when turn on the fan manualy the engine temp stays that way.
When i have the time, i install the bleed valve. I already did the white ring thing. So i only have to turn up the boost and fuel.

[nipper-1]

hello im new her i drive a td cavalier it now has a new engine so im slowley going to tune it as my last engine boiled .
on my old engine i did the white ring mod turned the on boost fuel up max fuel screw up a little cat and middle box removed was running at 1and a half bar
on my new engine i want to do every thing the same as the old one but i need more info! can any one tell me if removing the screw for stoping the revs from going over 5k
make any difference ive always removed it in my old cavs i know theres no point in reving it in to the red but will it help with fueling? for the pump to open up full?
im also going to try and fit a bigger turbo to my old manifold any one know what would be a good turbo to use? trooper or a t2 ? also dos fitting a bigger intercooler make much difference with the standard turbo? also what intercooler would be the best fit on a gsi cavalier bumper? ive been looking on ebay at NISSENS ALUMINIUM CORE RADIATOR < is this just a standard rad or dos it help cooling ? help plz

[KristofHA]

Hello,

I did the white ring thing, and installed a bleed valve. Do need to turn the screw on the dieselpump counterclockwise or clockwise to give it more fuel?

[Davcohen]

Hello,

I did the white ring thing, and installed a bleed valve. Do need to turn the screw on the dieselpump counterclockwise or clockwise to give it more fuel?

the opposite way you would think, so to up the fuelling turn it inward/ clockwise if your still unsure have the engine running as you adjust it and the revs will rise slightly

mark the original position and adjust it little by little trying it each time

[duckruls]

Hi, how do you guys find the induction noise when you have swopped to a cone filter ?

Previously I had a 1.5td with the usual boost/fuel tweak and a cone filter and the induction noise was quiet bad, I've now got another 1.5TD corsa and just popped a 1.7TD from a cavalier into it and with the cone filter its well noisey again.

Has anyone tried any alternatives to a cone filter ? maybe a different less restrictive air box ?

Cheers

[KristofHA]

Yes, it's noisy with a cone filter. When my windows is open, i hear the turbo blowing. But i like the noise of the turbo. it's not so "low profile", but it's better for the turbo. Stock the turbo takes the air on top of the engine, this air is hot.
Did't you also installed a intercooler for the 1.7?

[duckruls]

Thanks for the reply KristofHA.

I am going to try and modify the original airbox so the intake pipe is larger and re-locate it to the other side of the engine bay, hopefully it will help to redice the induction noise without restricting the engine.

I am planning to fit an intercooler but ran out of time when fitting the engine as I needed the car working, rather than bodging it up I will fit one when I have more time.

[KristofHA]

Your driving without intercooler?
keep the engine temp in mind, mine rise when i driving above 120 km/h on hot weather.
I fited a astra intercooler before i had the big intercooler.

I also thought of redirect the inlet to a stock airfilter. But because it's on the other side of the car and i have little room i installed the cone K&N airfilter.

Do you have some pic's of the engine bay?

[duckruls]

The 1.5TD corsa does not have an intercooler as standard, I definately need one and it is on my todo list.

I have cut and fibreglassed the original airbox today so that it will fit next to the battery, I will try to finish it off tomorrow and take a picture of it.

[Davcohen]

The 1.5TD corsa does not have an intercooler as standard, I definately need one and it is on my todo list.

I have cut and fibreglassed the original airbox today so that it will fit next to the battery, I will try to finish it off tomorrow and take a picture of it.

Relocating your airfilter closer to the turbo willa actually help with turbo lag, well it did on mine, personally i like the sound and thought it sounds much better then most dervs

http://www.youtube.com/watch?v=r80GYsw-D_I

i would also Decat it while you are there

[DutchNovaDiesel]

Hi, how do you guys find the induction noise when you have swopped to a cone filter ?

Brilliant !

[duckruls]

Here ya go KristofHA, here's the modified corsa airbox, the bottom and side have been cut off and fibreglassed up, the inlet pipe is 85mm diameter and goes down in the gap between the bumper and the wheel guard (K&N panal filter fitted):



Here it is fitted, still quiet tight getting it to fit:




Its now much quieter but still seems to drive the same so no obvious loss of power

Just need the boost controller to arrive as its still at the standard boost, the first one they sent to me was faulty.

What would be considered a safe boost pressure ? this is a family hack so I don't want it blowing up, I was planning on 1.2 bar ?

Davcohen - I've already cut open the cat and removed the filter and welded it back up

[Davcohen]

quite like the way you have mounted that, post up another picture or two, not quite sure how the valve could be faulty as its simple as anything either way once you get it on there id set it to around 1-1.1bar, mine is set to 17psi which is just over 1.1 bar without an intercooler and it quite rapid

[duckruls]

The airbox is not really mounted as such, its wedged in place and cannot move anywere, it fitted much better before I fibreglassed it but the fibreglass must have been slightly wrong as it is now a very tight fit.

The boost controller was faulty as it had no adjustment, I had the std boost pressure or with the slightest turn of the adjuster is was 1.5 bar, nothing in between was possible, its gone back now to be checked/replaced.

[DutchNovaDiesel]

The boost controller was faulty as it had no adjustment, I had the std boost pressure or with the slightest turn of the adjuster is was 1.5 bar, nothing in between was possible, its gone back now to be checked/replaced.

Or you need a stiffer spring, have you asked them if it's suitable for running 1.0 - 1.5 bar ?