Setting up a 300tdi properly

Now then is it worth me getting someone to set my 300tdi up properly , I get high Egt when towing and black smoke I understand this could be normal however I don’t knoe what’s been done to the engine previously. I’d like to know what I could do to increse towing power.
Based in East Yorkshire so any suggestions in the county or north Lincolnshire would be appreciated cheers

on my 300 tdi i fitted a bigger intercooler - slots straight in with no mods - and that has proven to be the single best mod I have done
lower egt's by a good 50 deg and motor just feels to breath a lot easier

What intercooler did you fit @D1Nut ?

Harry2000 said:

Now then is it worth me getting someone to set my 300tdi up properly , I get high Egt when towing and black smoke I understand this could be normal however I don’t knoe what’s been done to the engine previously. I’d like to know what I could do to increse towing power.
Based in East Yorkshire so any suggestions in the county or north Lincolnshire would be appreciated cheers

Click to expand...

Easy enough to check if you stick up a good close up picture of the injector pump.
If you remove the tapered boost pin you can see where the pin has mainly been running.

It's a sa made one but probably a copy of the cirrus one - they made 2 bigger versions - mine is the smaller of the two and slots straight in - I think the bigger one just needs the steel down plate to be bent straight

It probably makes sense to fit the biggest one first as the diff in price isn't that much

I don't think it cools the air by 40 percent more it' just doesnt feel reastrictive

I used to have a flat spot at about the 2500 rpm mark and that disappeared and then the boost kicks in at about the 1700 range and not the 2000 as it used to be

for me it's a good bang for buck mod

Would love to gas flow the head as someone else has done on here fairly recently - cant find that thread easily

People say putting a 63 mm exhausts on is also a damn good move - also removing the centre or first silencer box

My one buddy did this mod and the exhaust drone was horrible - but it did fly though

D1Nut said:

People say putting a 63 mm exhausts on is also a damn good move - also removing the centre or first silencer box

My one buddy did this mod and the exhaust drone was horrible - but it did fly though

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I was at the other end of that, I used to be a rally navigator in the 70s and we stripped / rebuilt our engine and I gas flowed it by eye (½ and fully round files, getting everything smoother by loading the file with chalk for a finer cut on a smooth file). When noise rules came in we had to add silencers to kill the noisy growl, it killed the power too. We had big bore exhaust pipework as well

300tdi's are not that powerful to start with, to be fair.

Your air and fuel mix needs to be right.
I'd suggest you start by sending the fuel pump and the injectors to be cleaned and refurbished.
Diesel Bob is just north of Preston.

As said above, a larger intercooler and exhaust pipe will also help the engine breath, to go the whole hog, a VGT/VVT/VNT turbo will also help, but you've just spent 2 or 3 grand to get to that point.

What ratio is your transfer box (RT230) ?
Have you got bigger tyres (than standard) ?

miktdish said:

300tdi's are not that powerful to start with, to be fair.

Your air and fuel mix needs to be right.
I'd suggest you start by sending the fuel pump and the injectors to be cleaned and refurbished.
Diesel Bob is just north of Preston.

As said above, a larger intercooler and exhaust pipe will also help the engine breath, to go the whole hog, a VGT/VVT/VNT turbo will also help, but you've just spent 2 or 3 grand to get to that point.

What ratio is your transfer box (RT230) ?
Have you got bigger tyres (than standard) ?

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Standard ratio 1:4 I think
265/75/r16
I get black smoke when turbo comes on boost so I presume it’s running rich on fuel so if I get more air in then I get less smoke more power so intercooler would be the way forward?

D1Nut said:

It's a sa made one but probably a copy of the cirrus one - they made 2 bigger versions - mine is the smaller of the two and slots straight in - I think the bigger one just needs the steel down plate to be bent straight

It probably makes sense to fit the biggest one first as the diff in price isn't that much

I don't think it cools the air by 40 percent more it' just doesnt feel reastrictive

I used to have a flat spot at about the 2500 rpm mark and that disappeared and then the boost kicks in at about the 1700 range and not the 2000 as it used to be

for me it's a good bang for buck mod

Would love to gas flow the head as someone else has done on here fairly recently - cant find that thread easily

Click to expand...

I was thinking of putting a vgt in to get boost earlier but If an intercooler can do it that sounds easier. Does it come as a kit?

Harry2000 said:

Standard ratio 1:4 I think
265/75/r16
I get black smoke when turbo comes on boost so I presume it’s running rich on fuel so if I get more air in then I get less smoke more power so intercooler would be the way forward?

Click to expand...

You seem to be trying to convince yourself that you need a bigger intercooler. A larger intercooler won't allow the passage of more air, a larger intercooler will 'cool the air more' due to it's larger surface/dissipation capability.

Take the pipe off that runs from the back of the air filter to the input on the turbo and try that (for a short while).
This will remove any restriction feeding air into the turbo and you will have maximum air input.
You could have an intercooler the size of a football pitch and you wouldn't get any more air into the engine.
A larger intercooler will not stop the engine producing black smoke.

If the engine is 'lumpy' on tickover/low revs, especially when cold' this is an indication that your injectors are spraying rather than misting fuel into the combustion chambers.
Black smoke is an indication that a diesel engine is overfuelling, or at least that the fuel is not being burnt efficiently.
Get the FiP checked over by a competent diesel pump engineer (Diesel Bob is good, there are others out there).

Harry2000 said:

I was thinking of putting a vgt in to get boost earlier but If an intercooler can do it that sounds easier. Does it come as a kit?

Click to expand...

It's just an intercooler - your existing hoses etc all attach as per normal

vgt is the ultimate answer though