You could get a "No Smoke, No Poke" sticker for the back window like most people with Euro look VWs' do in my area.

Hope you get it sorted, but it'll be painful with the standard map back on the car after driving with a remap for a while.

I doubt its the remap, a remap in real terms is a couple of lines of corrected code instructing the injectors to deliver fuel a fraction of a second early to create more HP and again once the piston has reached the highest stroke level to deliver a tiny bit of more fuel to create more torque, 160HP remap is only what the Disco had as standard, so your unlikely to have caused any issues at all. I have 180-190 in mine and I've had no issues at all for a year now, if your not holding it on the rev limiter and popping clutch on tarmac with grippy tires I can't see even the drive line suffering too much.

I dont think the disco td5 had anywheres near 160bhp as standard.
Knock 25bhp off and thats a bit nearer the truth.

Hmmm, I thought they had 160HP for some reason, OK

lightning said:

I did.

But they said it was normal to get a "a puff of smoke" when accelerating and maybe a cloud of smoke if it's been driven slowly for a while and then you floor it.

Click to expand...

One 'easy' way to clear a lot of smoke issues in any soot chucker is get a bottle of redex/your preferred brand and a new fuel filter, completely ignore the instructions on the bottle and just brim the fuel filter with the cleaner before putting it back on. Start her up and gently bring her up to decent revs for a good 5 minutes (you will notice when you are back on diesel). Hey presto! Reduced/no more smoke!

Well an interesting thing.

The Landy went into the main dealer today to get the ECU reset.
The engine is now a lot smoother. Before it was rough and vibrated at 2500rpm up to 3500rpm.
Now it is much smoother, sure it is not as fast but seems to pull pretty well through the gears.....certainly better than before it was remapped.
I wonder if they reset the injector codes? Or if somebody had messed with the ECU settings in the past?
Whatever, it now runs really well and is quieter too. Performance is pretty good too.
Maybe later in the TD5 production they improved the software, or used tbe Discovery map which had about 15bhp more than Defender.

I had a new ECU early this year (as well as a new wiring loom) to solve some problems on my TD5 (as detailed in my 'TD5 woes') thread. Since then I've noticed some performance improvements. If I'm overtaking lorries on the motorway I have to keep an eye on the speedo or I can find myself well over the speed limit, for example. As far as I know it's just a standard map, just like the previous one. So they seem to be sensitive to small changes.

I would imagine they updated the software as time went on.
Few Defender owners take their vehicle to a main dealer for servicing, so any updates won't get done.
I imagine l received the final software version, which may have been improved over my original 2004 one.

I used to own a Transit Connect van, and every time it went in for a service there was a "new software"

fullenglishpint said:

One 'easy' way to clear a lot of smoke issues in any soot chucker is get a bottle of redex/your preferred brand and a new fuel filter, completely ignore the instructions on the bottle and just brim the fuel filter with the cleaner before putting it back on. Start her up and gently bring her up to decent revs for a good 5 minutes (you will notice when you are back on diesel). Hey presto! Reduced/no more smoke!

Click to expand...

It might not work on the TD5 though, as after replacing the fuel filter you have to let the system self prime, which takes about five minutes, and the process may distribute the product back into the fuel tank without starting the engine.

This thread does interest me. As mentioned the R380 was named due to it being able to take 380nm torque (280ft/lb) but anyone who builds anything for mass production puts in redundancy, according to my engineer friend there is usually at minimum a 50% redundancy. So in theory that gives 570nm (420/ft/lb) before failure.

Plus on top of that there is the likes of TD5Inside (new Td5 is pushing 250bhp (tis a 2.8) and bundles of torque), Gigglepin (in the past) and a few other companies who use R380 boxes with a hell of a lot more power running through them than standard. Suppose the questions is longevity, but as mentioned as long as you stay sensible and dont try to get wheelspin etc... likely hood is the box will be fine. Also according to Giggle pin the Transferbox can take upward for 500bhp, again though longevity....

From what I have read and researched a re-map and larger intercooler with a boost tweak won't harm any of the transmission elements, unless you really push it hard. Mine has been mapped, larger intercooler, boost at 18psi, been that way for a year 5k miles, not had any issues as far as I can tell relating to the upgrades bar the clutch release bearing/spigot bush failing but there is no reason to assume they are related. To be honest I could not imagine going back to a standard Fender after building mine up to what it is.

As for the smoke issues, pre re-map (dynachip) I had zero smoke, ran very clean. After the map I did get a puff of black smoke upon changing gear however this went as soon as I fitted a larger intercooler. Since then runs as it did before just greatly improved.

I had a puff of black smoke thing too, when I fitted a new radiator I washed the intercooler out with acitone, no more puff of smoke since