200 TDI Boost Ring

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Right Gents, after 2 weeks of trying to figure out a way to remove one of the torx bolts by making my own tool, I've fitted the boost ring and I'm really pleased with the results. I already had the boost pin in but was getting severely sooty exhaust if I was going up hill in too low a gear. That has gone and I can easily now potter up hill all the way in 4th and 5th with no smoke it's really a nice difference. I can't say it's much faster but feels as if there's a little less effort required and less gear changes.
I've fitted an EGT which is a must if your fitting Boost Pins and rings as the scope for generating high temps is a lot broader with these tweaks.
I'm using all 3 shims and that seems ideal. I'll give it a few weeks and maybe drop down to 2 to see how that goes.
Really pleased with this mod.
 
Boost ring fitted today 200tdi defender engine, reasonably easy access, bet its not so much fun on the disco lump!
Havent driven it yet thats tomorrows job.

Ps I kin hate torx bolts they are always to shallow and are always hassle
 
The Mad Hat Man said:
Not till egt fitted. Need to get broken bolt out first :(.
Plus engine a bit rattly at 240k. May need a trip to Lincolnshire to get it looked at.
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Drill that bugger out. Take a file and smooth it flat as you can, then use a punch to mark dead centre. Then use a small bit first to tap a hole, then go to a larger bit. This relieve pressure on the thread as well as making way for an easy out bolt remover. It should ease out.
I haven't noticed a particularly big increase in exhaust temp either bit do get a gauge and see how yours heats up.
 
Ian Maycock said:
Right all boost ring fitted but will come to that later, sp00k can move actuator put mole grips on the arm at the turbo can move it with my thumb on the grips I'm guessing that its not stiff enough also the black rubber pipe from the actuator to the intake looks perished so think a rebuild might be in order.
Right now fitted the boost ring this morning, just to recap I've not messed with the pump apart from turning the fuel pin and lowering the star wheel 1/2 a turn the pump was rebuilt when I did my rebuild by a diesel specialist so it was standard and my turbo is only boosting at 0.8 bar.Fitted the boost pin yesterday and that made a bit of a difference mostly going up hills then this morning fitted the boost ring and personally I think it has improved it again. It feels more responsive and I achieved higher speeds in each of the gears also before she used to get to 60 mph and the struggle know she carry on to 70mph didn't try past that as the road wasn't up to it, also there is no smoke at all even when flooring it I even over took 2 horse boxes which I wouldn't have had the confidence to do before. I think she will improve further when I get the turbo sorted and maybe a small tweak to the power screw on the fuel pump. So all in all I'm pleased with the results.
So to any one thinking of fitting one its easy to do but very fiddly the how to video on Facebook at Fourby is good but , you might need to have some Irwin bolt and nut extractors ready as I did , the original screws holding the plate on are torx and its hard to hold the torx allen key in to get enough purchase on to remove as I think the might be locktited in, I got one out ok but the other one rounded slightly so used the irwins and she came out fine . Also the vid shows 2 springs in the housing mines a 200tdi and there was only one in there, don't know if this is right or I've got one missing , one of the more knowledgeable people on here might be able to tell me.
So there we have it I'm pleased with the results will post again next week if anyone interested and let you know what I think when I've been using her for a week and when I've got the turbo sorted I'll post again and let you know if there is any further improvement.
cheers Ian
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Only one large spring in mine.

Edit Ive just looked at the install video and the one the guy is doing has two springs but I did notice his cap was twice as deep as the one on my engine, his also had two washers/shim fitted and mine only had the one.
 
Last edited:
That's all I had in mine lynall , there must be a difference between the pumps on a 200 and 300 tdi , I think that's a 300 tdi on that video isn't it ?
 
lynall said:
Boost ring fitted today 200tdi defender engine, reasonably easy access, bet its not so much fun on the disco lump!
Havent driven it yet thats tomorrows job.

Ps I kin hate torx bolts they are always to shallow and are always hassle
Click to expand...
Had an epic with mine and Yes, too shallow. Well happy with results looking forward to hearing about yours
lynall said:
Only one large spring in mine.

Edit Ive just looked at the install video and the one the guy is doing has two springs but I did notice his cap was twice as deep as the one on my engine, his also had two washers/shim fitted and mine only had the one.
Click to expand...
I only had 1 original shim too.
 
Used one of them Irwin sockets on one of my torx bolts as it wouldn't budge came out real easy wish I'd thought about it and used in on both would have made life a lot easier. Will find out if the pumps differ my new project is a 300tdi so when I get round to the engine I'll have a look before I send the pump off for refurb.
 
Ian Maycock said:
Used one of them Irwin sockets on one of my torx bolts as it wouldn't budge came out real easy wish I'd thought about it and used in on both would have made life a lot easier. Will find out if the pumps differ my new project is a 300tdi so when I get round to the engine I'll have a look before I send the pump off for refurb.
Click to expand...
I think they are different
 
I've drilled and tapped mine did look at doing it whilst still in the Landy but thought there was to much room for error and didn't want to knacker the manifold . Also didn't want any swarf gating in the engine or turbo.
 
Ian Maycock said:
I've drilled and tapped mine did look at doing it whilst still in the Landy but thought there was to much room for error and didn't want to knacker the manifold . Also didn't want any swarf gating in the engine or turbo.
Click to expand...
shirley you are tapping the exhaust fannymould and, if the egr is blanked, then there is no chance of any swarf getting into inlet?

was thinking of magnetising drill n tap too.
 
Yes exhaust fannymould drilled right in the middle below were the turbo sits on, ahh just realised from some of your other posts above yours is a 300tdi isn't it mines a 200tdi so no EGR and turbo is on top of the manifold so limited access . The access might be better on yours.
 
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