Replace Intercooler, Fit Boost Gauge,Controller & EGT Advice

[damo667]

I've just purchased Boost Controller, Boost Gauge and an EGT from Trade me and I'm going to fit them to my 2.8TD Irmscher
First thing first though the intercooler was looking a bit fried so I got a replacement on Trade me for $20 (cheap I thought)

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Replacing the Intercooler seems like a very simple job but I thought I'de just check to see if there is anything that can go wrong just so I dont take it off and get stuck somewhere and have no transport whilst waiting for a part etc..
The main thing that concerns me is the gasket joining the exit pipe, should it be replaced?
There was a build up of oil around the gasket both on my old one and on the replacement.
Does this mean a leaky gasket or is it just a natural build up over time?

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Other then that it looks like a case of undo the bolts, disconnect the pipes and replace..
I've given the replacement a good degrease and flush and I'm currently waiting for it to be 'bone dry' before I fit it.

My next question is the EGT
There is a lot of discussions on here about the correct positioning of the sensor, as close to the engine on the exhaust manifold seems like the best place to get a true reading of engine temps..
I cant find any discussions relating to an intercooled engine though presumably I still need to fit the sensor somewhere between the block and the turbo as i need to be reading the temperature as it comes out of the engine.
Has anyone fitted on to the same 2.8TD intercooled 4jb1? I guess it would make sense to fit it whilst I've got the intercooler off.

Cheers for your continued help guys

[turnturn]

EGT gauge goes in the same place if its intercooled or not. It is reading Exhaust Gas Temperature (EGT) not intake charge temperature which is what the intercooler is dealing with.
Did you mean to say between the block and the turbo?

[geeves]

If you put a cup of kero in your intercooler and slosh it round for a while then pour it out you will be surprised how much oil comes with it. There is always a little oil coming out the breather and on a good motor it gets trapped in the intercooler. As the gaskets are not oil gaskets they do soak a little oil. Perfectly normal to be like this.
I cant see anything wrong with the old intercooler although there is a little fin damage its far from performance affecting

[damo667]

@turnturn sorry yes I've amended above
Thank you for confirming so would you recommend the same place as most others have suggested/fitted
In the manifold as close to the block as possible and make sure the tip is directly in the flow of gasses

@geeves thanks will do, good to hear about the oil residue
The old intercooler has probably %50 of the fins at the top folded over and and quite a few bugs/debry wedged inside and always annoyed me every tip I popped the hood..
I was going to take it off and try to straighten them all up and debug it but then I saw one on trademe for $20 and couldn't resist

Sorry guys new to all this turbo lark..

So I'm going to tee the boost controller into the pipe between the turbo and wastegate.. does the controller work buy reducing the pressure in the pipe stopping the wategate closing as quickly and keeping the boost going longer?

Also do I fit the Boost Gauge on the same pipe before the Controller I've seen it fitted onto the intercooler as well just wondering where to get the most accurate reading

Cheers

[damo667]

Got my EGT drilled in today, it felt a little loose and i didn't want to over tighten it as the manifold felt soft and easy to thread..
I was thinking to check it in a couple of weeks and if its worked loose I might put some exhaust paste on the thread in hope it will act like a 'locktight'
Got a couple of holes ready for my gauges to go in, just waiting for a mate and his tools to finish the job..
Also got the new and cleaned up intercooler on.. looks the part no more munted fins..

So I'm going to tee the Boost controller into the pipe 'pictured' between the turbo and waste gate as advised on here..
I'm just wondering about the boost gauge..

My Question is:

Does that have to go on the same pipe or does it go onto the pipe coming out of the intercooler 'pictured' as I'm sure I've seen it there before..

Cheers Guys

Damo..

[geeves]

Thats where my boost guage is fitted. You can buy the T piece from supercheap if the guage came without one but be careful The T piece should have a restriction on the pipe that goes to the guage. If its not there the guage will pulse at idle. Mine pulsed and even rattled with the wrong T piece. It did however read 2 PSI higher.
Idealy it should be as close as possible to the inlet manifold but I doubt that this location makes much difference

[damo667]

cool it came with a tee piece and it has a tiny copper grommet inside the tee off to the gauge so hopefully that'll do the job..
what about boost controller, do you have one fitted alan?.

[geeves]

dont believe in boost controllers belive it or not
I think my wastegates seized so it wouldnt do any good anyway
Without the restrictor I was showing 17 psi

[damo667]

Fair enough, I've heard their pretty hit and miss in less you get a good one.
I thought I'de give a cheap one a go and if it doesn't work I might just bring it down a shop in town that do a bit of tuning..
17psi!! I'll be happy with 15..

[damo667]

Got everything connected at the weekend.

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I wanted to mount the boost controller in the dash to make playing with it easier..

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I've just got to play around with the fuel and the boost now..

Hopefully finish my snorkel project next week..

Then Its the exhaust.. haven't even thought about it yet but have seen the odd 2.5 - 3m length of 2.5" stainless on Trademe cheap..

Couldn't have done it without Clubisuzu. cheers guys..

[damo667]

I've had a bit of a play and happy with the results.
Boost controller turned just about 3/5ths of a turn,
Fuel pump wound up 3/4's of a turn (anti-tamper already removed by previous owner so may have already been cranked)
After fitting controller boost was spiking to 17psi and then settling at 15psi when I turned the fuel up its sitting steady at 16..
The hills I were screaming up in second I now comfortably purr up in 3rd
Will be interesting to see what the fuel consumption is like now but hoping it wont be that different as I'm using less revs now to do the same distance..
Also my Egt's never seem to exceed the late 400's which is good as the exhaust is standard..

[jellis]

i have an egt guage and im wanting to put it on my egr blocking plate.
would this still give me an accurate reading

[damo667]

I would of thought so.. haven't done my EGR yet so haven't had good look at it..

[Captcol]

that is where I have seen other peoples, there is some argument about how far down the prob should sit, just in flow, mid flow or towards the bottom of the of the manifold.

[jellis]

sweet should get that done this weekend

[turnturn]

Worst case scenario would be that you are only measuring the temperature of one or two cylinders. All things being equal, this should be OK.

[jellis]

can i just drill a hole in the manifold prior to the turbo or will the little metal bits
destroy the turbo fins?

[mudslinger]

wouldnt it be better in the dump pipe after turbo? that way your measuring all the gases from all cylinders not jus one?

[geeves]

The temperature drops dramatically after the turbo due to the pressure drop plus the heat lost to all that metal. It has to be on the engine side of the turbo This is where the heat can cause damage

[Captcol]

I would take the egr plate off and drill and tap, then reinstall to reduce the chances of turbo damage