Time for an update,
So, since the rebuild she has been such a joy to drive and own, no other car has put a grin on my face in the same way this one does, especially since the remap.
The turbo is still working a treat with no seized vanes and the controller is still reliable and working well with the external wastegate.
Other than the routine maintenance, the only other mods have been carried out today and are possibly of interest to a few...
The picture below shows a few of my sets of injectors, in addition (not shown in the pic) are another set of standard 210 bar ZS injectors and the SDI injectors which were in the car when that picture was taken.
Top left, another set of standard ZS injectors
Top right 200tdi injectors
Bottom left, Dans clamps (before I finished them off)
Bottom middle, 300tdi injectors
Bottom right, 300tdi clamps (no use but they were sent with the injectors)
So I first made a set of hybrids using the standard 210 bar bodies and the nozzles taken from the 300tdi injectors.
Looking at the holes on the end, I double checked the angle which the injector needed to be rotated, it correlated perfectly with the angle Dan's clams were set at:
The difference in angulation required to place the spray holes correctly
The finished 210 bar/ 300tdi hybrids:
And the clamps:
I fitted them this morning:
First impressions were not good, lots of white smoke on start up and it was slow to start too, even once warm but it did get quicker as they day went on. Idle wasnt great either, fairly lumpy.
That is where the bad news ended though, I did a 70 mile drive with them and they were so much fun, in-gear acceleration can only be described as savage, much quicker than the SDIs.
Despite my car being quicker than ever, they need more work before Im happy with them so as soon as I got home I was straight in the garage making the second set of hybrids:
So for these, I dug out a second set of standard 210 bar ZS injectors and mated them with the nozzles from the 200 tdi injectors:
Left, 200tdi injectors
Right, second set of standard ZS injectors
Unlike with the 300tdis, you can see here the angle is the same between standard ZS nozzle and 200tdi nozzle:
So there we have it, the completed 210 bar/ 200tdi hybrids on the right:
First impressions of these are much better. It still pulls really hard (not quite as hard as the 300tdi hybrids lower down though) but it idles like standard and should hopefully fire up like standard too, Ill report back once Ive done a proper cold start. Being dark, I cant see exactly how much smoke they make but Im willing to bet there is a fair old cloud on hard acceleration.
So far though, the 200tdi hybrids are looking pretty good and the 300tdi hybrids have potential but I think require better atomization to improve the idle and starting, maybe increasing the break pressure above 210 bar would help? They are definitely amazing fun though just not for a daily driver in winter!