So we have now tidied up the fuel system pipework we mucked about with last week while searching for the source of the air in the system. Selected the aux tank after filling it with 20l of dieso, and once the engine was running it purged immediately. Superb!
Another option turned up for the fuel system return 'problem'. Rob 'Minivin' has suggested a system that he has proven before. Here the IP return is split to both tanks and then enters each tank through a std Series fuel pickup pipe which has been shortened to 1-2". As shown below.
The fuel will look for the path of least resistance so if the returns are kept the same length, then the fuel will go to the tank with the least fuel. The upside is at least this method reduces both the tank connections required and is easier rig. But, the downside is cross contamination from each type of fuel will then occur?!
So it's better than option 2 but not as effective as the swirl pot or alternatively another military tank selector valve. The latter would be better but I am still undecided.
EXHAUST SYSTEM
Firing the system up last weekend proved how loud the unfettered 200tdi can be. So I decided to do reduce the noise for now, and until I make a firm decision on the what will be finally fitted, I made a temporary exhaust.
The front section was made from the Series petrol downpipe welded to the 300tdi type turbo 3-hole mounting ring (minor mods to clear the LH engine mount). I then cut out the kink at the end then used another modified piece of the exhaust to give an exit just in front of the rear passenger wheel. No silencer either! But marginally quieter than before.
Note we have 1/4" clearance from the front spring shackle and 1/2" under the gbx x-member. Though it might look otherwise from the pics.
It may be planned as a temporary option, but it is tidy? ;)
(Note this section of pipework is only 1/4" smaller than the Disco tube!)
Also noted that when the engine is revved I am getting a lot of grey/unburnt fuel smoke. So maybe someone has tweaked the IP in the past - very possibly?
TURBO/HOSING
So no intercooler (for now) but I needed to sort out the inlet pipework and turbo outlet. Using some 50mm OD bends and a short straight section and a bit of jury rigging (blew off on the first blip of boost) it was good to go. I also used a bit of the old Disco flexible I/C pipework which was well past it's best so another length was ordered and will be here in a few days. I may replace with a complete welded section which would offer a better cooling surface area in lieu of a formal I/C?
The grubby bit of Disco steel pipework is going in the recycling and I have a nice bit of stainless to fit in it's place ;)
If anyone is after good quality turbo hose sections check these guys out. Cheapest I could find and very good quality. Venair-Performance-Silicone-Hoses
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