New intake, primarily to get rid of the standard intake bottleneck...

made from plastic pipe...

and with a new larger intake hole into airbox...

resulted in massive decrease in measured intake restriction.

New rear muffler (ex Jaguar resonator)...

Both modifcations resulted in car actually being slower...

as indicated by above traces showing actual on-road accleration at full throttle in second gear. This was most likely because the extra airflows resulted in leaner mixtures... which were fixed by a custom reflash resulting in a massive gain in actual on-road acceleration, as shown below.

Car drives exactly like a standard diesel 1.9 Roomster, but just with more power everywhere.

Really impressed with your work - sounds like a worthwhile conversion.

Does it make any difference to the fuel consumption?

My initial measurements indicate 5 per cent improvement.

Overalll fuel economy definitely better than standard, but improvement appears to vary quite a lot depending on driving conditions - from zero to about 7 per cent.

Am now fitting a better intercooler - standard intercooler's performance is pretty bad. In ambient temps of 20 degrees C, intake air temp is up to 60 degrees above ambient!

New intake, primarily to get rid of the standard intake bottleneck...

made from plastic pipe...

and with a new larger intake hole into airbox...

resulted in massive decrease in measured intake restriction.

New rear muffler (ex Jaguar resonator)...

Both modifcations resulted in car actually being slower...

as indicated by above traces showing actual on-road accleration at full throttle in second gear. This was most likely because the extra airflows resulted in leaner mixtures... which were fixed by a custom reflash resulting in a massive gain in actual on-road acceleration, as shown below.

Car drives exactly like a standard diesel 1.9 Roomster, but just with more power everywhere.

What did it do to your insurance?

John

standard intercooler...

...and new intercooler, taken from an Australian Falcon XR6 Turbo....

...complete with foam side pieces to stop airflow escaping.

The new intercooler is about twice as big as standard (and also has alloy end tanks rather than plastic that will help get rid of some of the heat).

Initial results indicate a peak temp gain over ambient of about 30 degrees C (20 degree ambient) as opoosed to the standard system's 60 degrees C above ambient.

Car is SLOWER with new intercooler.

Looks like another reflash will need to be done.

EDC15 apparently doesn't cope positively with any changes without being reflashed to provide the fuel to go with the extra air - I should have learned by going backwards with the intake and exhaust. Definitely do the reflash last!

Edited 14 December, 201015 yr by Julian Edgar

...however, even without another reflash, fuel economy has improved.