K quick summary for lazy people
I have popped in a set of very aggresive injectors that require an upgraded turbo - I went for a hybrid version of the GT 1549 - it has been machined out and strengthed to shoe horn the parts from a TD5 unit. Can't get anything bigger unless get a larger turbo - that has additional lag issues and custom pipework etc...
I have had a gearbox uprated and a quiafe atb popped in - clutch uprated to a Helix cerametalilc sprung plate with a helix uprated cover - is quite aggressive but it can cope with the torque
Hydraulics have been whipped out as the OE stuff would have done a 180 impression and broke - with a part list from a guy on .org and rally matt's approach got a custom set made up using rover600 parts - Sheddist kit is not available for a diesel (but will be soon i read)
After this was fitted i took it down to see Matt Reidy, and the clutch slave cylinder mounting bracket sheared while it was on the Dyno... had only got as far as taking fuel out - back to rally Matt to get that sorted and car was with me again end of novemeber...
before i got it booked in with Matt Reidy, i blew the Head gasket - went between the fire ring on number 4 - typical place for the L-series and the prima perkins before it...
To stop this happening again - as it was casued by the turbo boost and fuel, we have got some ARP head studs fitted to it, Matt has treated the HG with some special copper sealant. He has also done some porting work on the head while it was off, and fitted a racing spec Huge FMIC to it, which we built thermocouples into it on either side to get inlet and outlet temps.
Being the perfectionist that Matt is he has spent a fair bit of time identifying the most effective pipework combination for the FMIC and lagged exposed metal bits to help with engine bay temps...
I have however just found out that the head can cope with the increased temps, but the coolant system does not seem to be able to - it just threw the coolant out the top of the expansion bottle when the pressures got too high
I have also got a thermocouple hooked into my blanked EGR system to read the exhaust gas temps - they are hitting 800C+ when on full boost, so still a bit hot...
As it is throwing its toys out the pram a bit, i think i need to get to down to see matt before any dyno runs are made, but we need to wait for a new centre section to arrive as mine just went.. typically...
From HG blowing to now has been about 7 months, hence why i am quite excited
Figures could be as much as 200bhp, but i will be happy with 180 (or less tbh). Torque is likely to be limited to around 270lbsft from 2000rpm to about 4000... but this is all dependant on Matt's Magic with his mapping
the setup i have got can probably take 310 plus - as we have seen another L-series return those figures, however i am not sure that that would be sustainable long term, even with the effort we have gone to....
It is the high compression ratio of this engine that is giving us the good figures\economy, but hampering our tuning. it is 19.5:1 - mine will be a touch higher as it has been skimmed
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