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  #81  
Old 10-10-2018, 10:24 PM
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What airbox are you running mate? Any improvement in economy?
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  #82  
Old 11-10-2018, 08:51 PM
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So whats made the best improvements to the CRD zd30 you ask?

more air through the airbox is a big difference. K&N filter and cobra head.
2.5" turob inlet made a very big difference. stopped a lot of turbo flutter
Swirl mod for low down torque
wrapped dump pipe
3" exhaust
auto line resistor mod to prevent auto flare.
Tillix and in cab needle valve. the in cab valve is nice so adjustment on the run can take place.
bigger intercooler (ebay HPD copy top mount) still dreaming of a front mount.
running 33's on stock diff ratios.

best non performance mods? sound deadening the whole car + heat insulating the roof
rear locker overspeed chime kill
main tank expansion mod - extra 12L of fuel gives a nice improvement to range.
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  #83  
Old 23-10-2018, 08:53 PM
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just ordered a TB48 thermostat for the zd. this will be fun...

Also have the resistor to alter the pink wire coming from the MAF.... here's the resistor in question. https://www.jaycar.com.au/6-2k-ohm-0...ietQKXkLyeNFd8

after a quick drive after doing the mod it seems the flat spot down low has gone. the pink wire is the temp sensor i've been in formed by Mal.

I was sure there was an element of temp control in the maf, so I insulated mine a year ago. This evening i've removed the insulation off the maf housing as the resistor should do a better job than the insulation ever could.

I hard wired in (soldered) the resistor for the boost controller, I'll get around to doing the same with the EGR butterfly swirl controller next time the intercooler is off.

No codes from doing any of these which is excellent news! Will report back when the next tank of fuel goes through.
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File Type: jpg boost controller rewired.jpg (27.8 KB, 234 views)
File Type: jpg no codes.jpg (16.5 KB, 237 views)
File Type: jpg cobra head insulation.jpg (31.7 KB, 233 views)
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  #84  
Old 24-10-2018, 09:31 PM
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so no CEL or codes have been thrown since doing these mods. the wiring around the airbox has been cleaned up by removing the factory vac controller, have taped the boost controller wiring to the MAF wires.
So for the fun part. this morning i was wondering if my VDO EGT gauge was broken cause temps were sitting a good 50 deg lower under all conditions. Took it for an extra spin around the block from work to find a good hill to climb up.
This evening i drove up the biggest hill in town, and for the first time i was able to accelerate up the hill, and temps didnt go over 450, in the past it could easily hit 500 and i'd back off. water temps are sitting back at 88/89, highest was 92 driving up the big hill. so for now I'd say the maf pink wire (temp signal) resistor mod is great little 5min mod.
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  #85  
Old 25-10-2018, 02:41 PM
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Quote:
Originally Posted by mad possum View Post

Also have the resistor to alter the pink wire coming from the MAF.... here's the resistor in question. https://www.jaycar.com.au/6-2k-ohm-0...ietQKXkLyeNFd8

after a quick drive after doing the mod it seems the flat spot down low has gone. the pink wire is the temp sensor i've been in formed by Mal.

I was sure there was an element of temp control in the maf, so I insulated mine a year ago. This evening i've removed the insulation off the maf housing as the resistor should do a better job than the insulation ever could.
Hi mate, what's the underlying theory behind the pink wire resistor on the MAF?
"Flat spot down low has gone" sounds like something I want to achieve.

Edit: just found it on ZD30 Warriors. Looks to be a great mod. @geeyoutoo you can delete this post.
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  #86  
Old 27-10-2018, 08:33 PM
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No further CEL codes, no other issues/codes. EGT's still sit lower than before, and slower to rise.
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  #87  
Old 28-10-2018, 12:14 AM
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Dan, read thru your thread and looks like U are yet to do remap. Understand remap negates the need for the swirl valve mod.

Interested in the MAF temp sensor pink wire (resistor in series mod). I do not experience a flat spot low down. The EGT drop looks beneficial. Currently run good EGTs with my CRD eng mods, Procharge h/f stage 3(maxB 26psi), improved induction, JT cooler, NADs / manual boost control etc.

From what U understand, would the MAF resister mod provide a gain for all CRD eng modification variants?

Also what exhaust heat wrap product did you use?

John
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  #88  
Old 07-11-2018, 07:24 PM
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Quote:
Originally Posted by JT54 View Post
Dan, read thru your thread and looks like U are yet to do remap. Understand remap negates the need for the swirl valve mod.

Interested in the MAF temp sensor pink wire (resistor in series mod). I do not experience a flat spot low down. The EGT drop looks beneficial. Currently run good EGTs with my CRD eng mods, Procharge h/f stage 3(maxB 26psi), improved induction, JT cooler, NADs / manual boost control etc.

From what U understand, would the MAF resister mod provide a gain for all CRD eng modification variants?

Also what exhaust heat wrap product did you use?

John

Hi John,



exhaust wrap ive used on the last 2 patrols ive had were ebay spec. both have worked well and lasted. Dump is the most important to wrap.


I've heard of remaps that you dont need to use the resistors on, and multiple ppl who have had a remap and still benefitted from the resistor mods. Not all remaps are equal and we finally have the proof.
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  #89  
Old 07-11-2018, 07:33 PM
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So today I got the hot side IC pipe replaced.
1.75" to 2" adaptor
2" 60 deg into
2.5" and mig welded
2.5" into 2.5" I/C inlet.

As is to be expected, i've lost a little low down boost but midrange has benefitted substantially. very happy trade off. dont need that punch of the line just to have it die soon after. all engine mods are done for remap now so no more excuses.

Btw, the maf resistor mod (pink wire) seems to have made a big difference fuel wise, just under 1/2 the main left and already done over 720km (sub tank included). usually i'd be sitting on 600km at this stage or less if mainly driving around town.
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  #90  
Old 12-11-2018, 06:14 PM
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12.5L/100 is nothing to be scoffed at in a CRD zd30, but thats what I got last tank! did 550km yesterday and it looks like even better is on offer. drove up to 'the town of 1770'.

side note, amazing spot, really great views etc.

EGT's were below 300 at times sitting on the freeway at 100, the engine ran really smoothly and had plenty of power. So it seems upgrading the intake pipe was worth it, and the maf temp resistor mod has paid itself off and some!
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  #91  
Old 13-11-2018, 08:11 PM
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so question.
If i fit a TB48 thermostat the coolant should remain cooler. Coolant currently sits on 89-90. TB48 thermostat should drop coolant temp to around 84 deg.
Coolant temp and oil temp should be closely mirrored. I have been running full synth 5-40 Nulon. Now in a warmer climate I was planning on running 15-50. However if my oil will be running cooler (hopefully it will sit around 84 deg) should i continue running the lighter 5-40 or still switch to the heavier 15-50?
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  #92  
Old 14-11-2018, 06:50 PM
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Could be worth looking at the warm climate thermostat. I know for the tb48 they make 78, 84 and 88 varieties, I'm sure the zd would have the same options

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  #93  
Old 14-11-2018, 07:15 PM
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hmmm might have to go back and check the one I have...
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  #94  
Old 14-11-2018, 08:19 PM
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cant seem to find a list of part numbers for thermostats and their operating temps.

The one I have waiting on the shelf is 21200vc200. if anyone knows its operating temp that would be great!
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  #95  
Old 22-11-2018, 07:18 PM
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ha, turns out it's stamped on the thermostat itself! 76.5 deg. that will do for me. how to find out the details of the CRD glow up sequence. sure its more complex than just the first 30 sec...
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  #96  
Old 26-11-2018, 01:12 PM
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ECU got mailed today, off to ECPT, just couldnt beat them on price and time. Living in Hervey bay i'd have to travel to get a remap, and wait a day somewhere for it to be done. I know i have all the mods done to support it and can adjust my tillix myself after, just would have been nice to get a dyno print out.
So the big questions will be,
1. drivability
2. absolute power
3. economy
4. EGT's
Look forward to seeing this develop now.
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  #97  
Old 26-11-2018, 02:14 PM
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Quote:
Originally Posted by mad possum View Post
ECU got mailed today, off to ECPT, just couldnt beat them on price and time. Living in Hervey bay i'd have to travel to get a remap, and wait a day somewhere for it to be done. I know i have all the mods done to support it and can adjust my tillix myself after, just would have been nice to get a dyno print out.
So the big questions will be,
1. drivability
2. absolute power
3. economy
4. EGT's
Look forward to seeing this develop now.
1. You will think it's a different vehicle.
2. Maybe not a huge increase, but hp and torque will come in significantly lower.
3. Eco 'may' go south just a little, but as long as 1 and 2 are positive then you may not mind
4. EGT's 'may' go up a touch depending on how driven.
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Old 26-11-2018, 04:33 PM
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Quote:
Originally Posted by mad possum View Post
ECU got mailed today, off to ECPT, just couldnt beat them on price and time. Living in Hervey bay i'd have to travel to get a remap, and wait a day somewhere for it to be done. I know i have all the mods done to support it and can adjust my tillix myself after, just would have been nice to get a dyno print out.
So the big questions will be,
1. drivability
2. absolute power
3. economy
4. EGT's
Look forward to seeing this develop now.
Did postal with Harley 12 months ago and yeah he has his firm price (fair), lots of demand on his time and excellent follow on support.

I was pleased with driveability, ran max boost 21-22psi (up from around 16-17psi with stock ECU) and as a consequence achieved slightly lower EGTs (test hill 550 down from 575 DegC) and eco hwy 12.5l/100ks down from 13.5 l/100ks (stock induction).

Lot of changes since then, had Harley do tune on rollers (May 1 with 3" induction (fabwitz)/Procharge stage3 turbo (max B 26psi) with improvement of EGTs (reduced by 25 degC and better performance (kW/N-m).
Subsequent to this, recently installed JT cooler that provide lower EGTs (up test hill) now @ 425 DegC with fuel running up 13-13.5 lt/100ks o/a. The cooler gave me 100 deg C plus improvement of EGT up test hill.

Now gathering pieces to install 4" thru airbox (9" K&N pod filter) and 4" snorkel (fwd facing with 4" safari ram hd) and then will visit Harley again new yr for another tune..

Pic of new airbox that arrived today.
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  #99  
Old 26-11-2018, 05:13 PM
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Quote:
Originally Posted by geeyoutoo View Post
1. You will think it's a different vehicle.
2. Maybe not a huge increase, but hp and torque will come in significantly lower.
3. Eco 'may' go south just a little, but as long as 1 and 2 are positive then you may not mind
4. EGT's 'may' go up a touch depending on how driven.

I understand that is a possiblity, one reason i went with ECPT because it's a 'known' map.
Remap will allow increased boost but without increasing fueling there's no more power available, so consumption should go up slighty. got 13.5 last tank, would love to see 12's.

Will be interesting to see how she drives once done, i'm looking forward to having enough power to make it up hills without loosing 20km/hr.

This may make auto lock up something I can't put off any longer.
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Old 26-11-2018, 05:21 PM
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Quote:
Originally Posted by JT54 View Post
Did postal with Harley 12 months ago and yeah he has his firm price (fair), lots of demand on his time and excellent follow on support.

I was pleased with driveability, ran max boost 21-22psi (up from around 16-17psi with stock ECU) and as a consequence achieved slightly lower EGTs (test hill 550 down from 575 DegC) and eco hwy 12.5l/100ks down from 13.5 l/100ks (stock induction).

Lot of changes since then, had Harley do tune on rollers (May 1 with 3" induction (fabwitz)/Procharge stage3 turbo (max B 26psi) with improvement of EGTs (reduced by 25 degC and better performance (kW/N-m).
Subsequent to this, recently installed JT cooler that provide lower EGTs (up test hill) now @ 425 DegC with fuel running up 13-13.5 lt/100ks o/a. The cooler gave me 100 deg C plus improvement of EGT up test hill.

Now gathering pieces to install 4" thru airbox (9" K&N pod filter) and 4" snorkel (fwd facing with 4" safari ram hd) and then will visit Harley again new yr for another tune..

Pic of new airbox that arrived today.

New airbox looks good!! so much still to do on mine! one day i'll get a turbo upgrade took me 2 years to get a remap lol
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