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Intercooled 4x4; Tdi
Topic Started: Jan 5 2013, 10:38 PM (3,272 Views)
richc-101
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my truck now has an intercooler fitted, driven it 100 miles back
home from Cinderford

Its definatly improved pulling away from a standing start, and on steep
hills its allows me to stay in a higher gear.

Crusing it just makes progress better, it'll see the high side of 60 on
the speedo easily (the speedo over-reads) and copes with the rise and
fall of the road better. All in all very pleased and impressed, its alot
more relaxing driving now

The way it was done was to use a manifold from a xx-12 4x2 truck. You
can turn the kkk turbo on this manifold so you can get the pipes to run
correctly. The other part you need is the inlet pipe to the engine which
on our trucks is vertical but on a xx-12 truck is horizontal (you can
buy this part from iveco for 70 quid or so)

Mine was a custom built intercooler from allisport (www.allisport.com) ,
i'll post pictures soon

I do have a standard Iveco intercooler and pipes for sale now if anyone
wants to have a play

Rich
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Ned
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yes please Rich pics would be great. i dont understand the Engilsh reg plate system, what year veko was the manifold from?

regards
redd
Edited by Ned, Jan 7 2013, 09:24 PM.
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Bazil-S
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Hi,

Excellent job, you have managed to increase the engine power... but it can be a little more. It is time to think of injector nozzles with a better atomisation and a pump setting for 120Hp.
It would be useful a description of the modification, perhaps accompanied by some pictures, unfortunately I can not do this anymore (the pictures), I no longer own a second generation Daily.

Kind Regards.
Bazil-S
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Ned
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do you know the part number of the improved nozzles Bazil?
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ivecojoe
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I have mk2 intercooler radiator turbo and various hoses bought to fit one of my previous trucks to uprate it but then bought a newer turbo model.....so if anyones interested i am in southampton england. cheers tractor paul.
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Bazil-S
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Ned
 
Improved nozzles require only 2.5L engines.
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Ned
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sorry Bazil I dont understand. do you mean the nozzles from the 2.5 are the improved version? i have a chain driven 2.8 103hp
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Bazil-S
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Sorry, I expressed myself wrong. 2.5L engines (type 8140.27 S) are the only ones who need improved nozzles. Not applicable for your engine.
Edit:
It is about nozzles with 5 holes instead of 4 holes, 5 holes nozzles have a better fuel atomization and a better flow. All 2.8L engines have nozzles with 5 holes.
Daily4X4 engine power is around 100 horsepower and can be increased to 120 hp.
This topic I do not really want to open it because most engines have many miles on board, so they have mechanical wear and any power increase under these conditions will lead to their destruction.

I'm sorry that I made some comments on this topic.
Edited by Bazil-S, Jan 11 2013, 07:38 PM.
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richc-101
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Ned
Jan 7 2013, 09:17 PM
yes please Rich pics would be great. i dont understand the Engilsh reg plate system, what year veko was the manifold from?

regards
redd
No idea - it came off a spare engine I bought off Mark Hadley.

I think any xx-12 engine manifold (in your case 2.8) would probabily fit

The other bit you need is the intake pipe from an xx-12 engine

use the same turbo, i'll look at the parts book and see if we can get part numbers





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Ned
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cheers Rich, cheers Bazil, thanks for the explanation
Edited by Ned, Jan 13 2013, 10:16 AM.
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richc-101
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Ah , that explains where the 5 nozzle injectors a mate of mine was talking about come from

So they are 2.8 parts.

My engine was rebuilt only 40k klicks ago so is like new , may look ito this oce my mate has done it and tested , he reccons another 10 horses o top of the 20 or more the intercooler will give


Have take photos will post tomorrow if i get a moment


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Bazil-S
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Hi,

Daily XX.10W (4X4) - engine type: 8140-27; 2.5L 103HP

Default Nozzle Bosch type DLLA 150 P 205 Bosch ref. 0433 171 171 Iveco:4845692 Technical Data: 4x0,30x150o

Daily XX.12 - engine type: 8140-47; 2.5L 116 to 120Hp

Default Nozzle Bosch type: DLLA 160 P 85 Bosch ref. 0 433 171 08 Iveco:4796259 Technical Data: 4x0,29x160o

Improved Nozzle Bosch type: DLLA 150 P 235 Bosch ref. 0 433 171 193 Iveco:98409842 Technical Data: 5x0,28x150o

ie: 4 holes x 0.30mm at 150 degrees

Edit:

ENGINE: 8140.47.2700

Injection pump data: https://dl.dropbox.com/u/14168135/Turbo%20Daily%20Fuel%20System.pdf

Even though the 2.5L engine, of 103 horsepower, have a different type of pump, can be made the settings from attached documents
Edited by Bazil-S, Jan 14 2013, 08:00 PM.
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Bazil-S
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richc-101
 
If I remember correctly you have a 120 horsepower engine for spare. Use the spare injection pump, but not before it is set on a test bench. When assembling the pump on engine is very important to set the injection timing with a gauge.
Replacement of nozzles and pump setting is expensive, a single nozzle can cost 40 to 50 pounds without mounting labor and injector adjustment.
The injectors adjustment will be made at 230 bar, even if the book says 240 bar.
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richc-101
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No my spare engine is a 2.5 that was messed about with by a gy who had access to Iveco parts very cheaply, I need to pull the injectors and take a look at them to see if they have been swapped too

Do I need a special tool to remove injectors ?

Rich



photos


Bazil-S
Jan 14 2013, 07:33 PM
Hi,

Daily XX.10W (4X4) - engine type: 8140-27; 2.5L 103HP

Default Nozzle Bosch type DLLA 150 P 205 Bosch ref. 0433 171 171 Iveco:4845692 Technical Data: 4x0,30x150o

Daily XX.12 - engine type: 8140-47; 2.5L 116 to 120Hp

Default Nozzle Bosch type: DLLA 160 P 85 Bosch ref. 0 433 171 08 Iveco:4796259 Technical Data: 4x0,29x160o

Improved Nozzle Bosch type: DLLA 150 P 235 Bosch ref. 0 433 171 193 Iveco:98409842 Technical Data: 5x0,28x150o

ie: 4 holes x 0.30mm at 150 degrees

Edit:

ENGINE: 8140.47.2700

Injection pump data: https://dl.dropbox.com/u/14168135/Turbo%20Daily%20Fuel%20System.pdf

Even though the 2.5L engine, of 103 horsepower, have a different type of pump, can be made the settings from attached documents
Vexi price for injectors is £100/piece

Maybe I'll do without that extra 10 horses

Rich
Attached to this post:
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Attachments: IMG_0014__Large_.jpg (41.19 KB)
Attachments: IMG_0015__Large_.jpg (47.8 KB)
Edited by richc-101, Jan 23 2013, 08:52 PM.
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Bazil-S
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Yes indeed, this type of nozzles are disappearing from the market and became expensive. However, you can try to search after Bosch code. To remove the injectors you need a puller, there are plenty on Ebay.
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