540is

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...with TD5Alive Hybrid turbo - TD5Alive Intercooler, de-cat & fullflow exhaust, de-egr
and proper custom map. :confused:
 
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and what else should i consider upgrading - without opening up the engine.
are the OE injectors suffient?
 
Yes ofc. - the hardware & driveability sets the limit. - but I suppose there must be a few of these TD5's out there running TD5Alive or likewise....

let me rephrase: with HW above - will I be able to get 180hp/220lbft still good driveability and mpg?
 
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Yes ofc. - the hardware & driveability sets the limit. - but I suppose there must be a few of these TD5's out there running TD5Alive or likewise....

let me rephrase: with HW above - will I be able to get 180hp/220lbft still good driveability and mpg?

I should bloody hope so considering a TD5 should make that completely standard! :p
You should be able to easily get 180bhp with just the re-map, exhaust and intercooler

With the Hybrid turbo, Intercooler, good exhaust and map, you should be looking at anything from 200-250bhp and 330-360lbs/ft I'd imagine.

Mpg will all depend on the way you drive it and what other stuff your carrying or what wheels and tyres/transfer box your running. Should manage around 30mpg with easy driving though.


I have more or less all the same mods but they are Alisport/Bellauto VNT turbo, Alisport exhaust manifold, Intercooler, EGR delete, silicone hoses, De-cat, straight center pipe. I haven't got mine mapped properly for the new turbo yet but I'd be hoping for around 230-240bhp and 480-500Nm
 
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...with TD5Alive Hybrid turbo - TD5Alive Intercooler, de-cat & fullflow exhaust, de-egr
and proper custom map. :confused:

you can get the stuff cheaper I believe from other sources then use there ecm system. Alisports seems to have good prices, plus they have a very nice exhaust header, cast iron that does not seem to warp and will have a better flow.

On another note alisports does a off road intercooler that has the fins further apart for easier cleaning of mud and dirt
 
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Yes ofc. - the hardware & driveability sets the limit. - but I suppose there must be a few of these TD5's out there running TD5Alive or likewise....

let me rephrase: with HW above - will I be able to get 180hp/220lbft still good driveability and mpg?

yes few have the 225hp and are happy campers. The mpg is how you manage your right foot, drive like you got a egg under it and good mpg. Drive it like you stole it then less mpg;):)
 
and what else should i consider upgrading - without opening up the engine.
are the OE injectors suffient?

Halfshafts and CV-joints :D

Replace the exhaust manifold bolts with the stronger and longer ones too to help stop the prick of a standard manifold warping or pulling the studs. Or you can go with the upgraded manifold from Alisport like mine and as Thor has mentioned already but it's pretty expensive!!! :(
 
Halfshafts and CV-joints :D

Replace the exhaust manifold bolts with the stronger and longer ones too to help stop the prick of a standard manifold warping or pulling the studs. Or you can go with the upgraded manifold from Alisport like mine and as Thor has mentioned already but it's pretty expensive!!! :(

Thing is it will save on expensive repairs down the road, and handle the extra hp. My view is if you are wanting extra hp, you will need to replace the exhaust manifold down the road. So your replace it along with a vnt turbo and inter cooler. you sell them parts on as good used and recoup some of you costs
 
Yep, I was sick of the standard one after having to fix it twice and that's even before the VNT!

Suppose the fact I do quite abit of heavy towing, there's long periods of sustained relatively high boost with the other mods so that's what done it. The Bigger intercooler helped though I reckon as the second one lasted a little longer.

I have a mill though so I'll just skim my old ones and they'll do for anybody that needs a good standard one.
 
Thanks for all replies - ill consider the manifold - is Alisport the only option? or
is there any other ones around - ie any tubular ones rather than casted ?
 
Thanks for all replies - ill consider the manifold - is Alisport the only option? or
is there any other ones around - ie any tubular ones rather than casted ?

you don't want tubular they rust and do not carry the heat away. If you get along and searching/looking at the different makers of parts It will give you a better idea of what is out there.
What kind of money are you wanting to spend, as that is the controlling factor
 
I fitted mine during the week. Manifold was a welcome change and I gave it a pretty good test the other night with pulling a trailer loaded up with a V6 Shogun and it didn't miss a beat.


Mine is only boosting to around 1.05-1.12bar though with the VNT so must look into that and see must I change anything.

Low end torque is awesome though!
 
I fitted mine during the week. Manifold was a welcome change and I gave it a pretty good test the other night with pulling a trailer loaded up with a V6 Shogun and it didn't miss a beat.


Mine is only boosting to around 1.05-1.12bar though with the VNT so must look into that and see must I change anything.

Low end torque is awesome though!

you need the thing to fool the ecu as that is limiting your boost and if you do over boost you go to limp mode.
 
you need the thing to fool the ecu as that is limiting your boost and if you do over boost you go to limp mode.

Fitted an Alisport boost box at the same time though which should sort it. I'm not sure if it's working though... Checked the male/female connection eariler and clamped them just in case they weren't making perfect contact. I'll try the earth wire next although that should be good as it's onto the earth stud underneath the fuse box.
Am I right in that there's not really any adjustment needed on the VNT other than the stop to keep the vanes closing down completely?

Haven't fitted a MAF bypass pipe yet but not much need if I'm only making standard boost so far :eek::p
 
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Fitted an Alisport boost box at the same time though which should sort it. I'm not sure if it's working though... Checked the male/female connection eariler and clamped them just in case they weren't making perfect contact. I'll try the earth wire next although that should be good as it's onto the earth stud underneath the fuse box.
Am I right in that there's not really any adjustment needed on the VNT other than the stop to keep the vanes closing down completely?

Haven't fitted a MAF bypass pipe yet but not much need if I'm only making standard boost so far :eek::p

Thought it was plug and go, follow instruction
 
Yea, that's what I was thinking. I'll give Alisport or Bells a ring tomorrow to see if I'm missing anything.

I have a Safari snorkel alright that would be a little more restrictive than a standard vent but can't see it being the make or break of it.
 
:eek::eek::eek:

Was chatting to Pete this morning about it. I knew it was something stupid lol.

Seeing as the Nanocom gets it's readings from the ECU, naturally when the ECU is being fooled by the boost box it is still seeing a max boost of 1.1 bar or so and then relays this to the nanocom.

Incentive to finally get that pod and fill it up with a proper boost gauge and maybe an EMSII :)

I'll get it re-mapped then again to see how far it'll go
 

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