harvey

iTrader: (48)

The Vectra MY06 1.9 Diesel. CDTi SRi 150.
(OE car = 150 bhp 236 ft.lbs)

Hand made exhaust.
Hybrid GT Subaru FMIC.
49 diameter compressor wheel swapped for 56 diameter and compressor cover machined.
Minor air box mod.
Will still return 50 mpg.
More to come ............

dan83590

Any smoke from it like that?

harvey

iTrader: (48)

There was previously and it was a concern but now it is clean after some further work to get more air in.

dan83590

This diesel tuning lark is getting ever more popular. Who modded the turbo, you? How much more air does the larger wheel push through, does it make a big difference to how much more fuel can be burnt?

Oh-Flock

iTrader: (10)

thats a great result harvey

i take it you have posted that up on a vectra forum

could be another sales avenue for your front mounts

Norman Dog

iTrader: (1)

It's still a Vectra. Which is not a good thing.

alcazar

iTrader: (2)

Care to elaborate?

chocolate_o_brian

iTrader: (22)

Keeping it standard looking outside would leave you a German rep slayer on the m'ways Harvey

alcazar

iTrader: (2)

LOL. Have you told your wife you've done this Harvey?

harvey

iTrader: (48)

I modded the turbo but got our local machine shop to bore and profile the compressor cover to the 56 wheel that cost me nothing. I have not calculated the additional air over standard because the data log is stuck around 172 g/s so I have either maxed out the MAF Sensor or the turbo but if I do some more work tomorrow I will identify that. I suspect the car comes with a 2.5 bar map sensor so now I need to find a 3 or 4 bar that will fit in place of and I guess Bosche will have such a thing in their range.
I don't know what size the injectors are but they are not maxed out yet so if I can get a bit more air I can still add fuel. From what I have found all you have to do is give it fuel and boost to get power but to get clean power you need to get the air right.
Yes Phil, the Hybrid GT FMIC made a big difference and it was easy to fit. Having done it once it takes half the time of fitting a Subaru FMIC, only the core and some silicon pipes and I used two brackets from a WRX TMIC.
Yes it is still a Vectra, my Wife's car and other than a boost guage and ACT guage it looks like any other Vectra except it will show any standard WRX a clean pair of heels. The trip computer tells lies but actual fuel consumption on a fairly fast long distance trip is usually over 50 mpg and even when it gets the beans on short journeys we have around 40 mpg going down to low 30s on track.
I havn't been able to check yet but if it will pull the red line in 6th with the current wheels and tyres, top speed will be something like a 164 mph and it certainly exceeds 150 mph according to the Sat Nav when the speedo is close to 160 mph.

mervil

iTrader: (5)

Good effort Harvey That'd make a nice second car

harvey

iTrader: (48)

Merv: Yes at over 50 mpg out of town it can go more than twice as far as any of the Scooby Wagons I have and from A to B it is not any slower and it does not attract attention. There is a lot of fun to be had.
I have just been out and confirmed the MAF sensor is maxed out at 172 g/s approx but that is not as bad as it would be on a Scooby because the MAF does not control the fuel. Fortunately that means there is a little bit more in the turbo so the objective now is to see how much more I can get reliably. From the datalog information I have recalculated the top speed and if it has enough power it will max out at 172 mph on the current wheel and tyre arrangement

dan83590

Great stuff Harv. I do like seeing the 'out of the ordinary' made to go o o o

chrispy200+

iTrader: (2)

Have you removed the dpf on it to get to this power or does it not have one?

harvey

iTrader: (48)

This car was not fitted with DPF, these came on the Vectra a few months later. However I understand there is generally more potential for power out of the DPF equipped cars because they are fitted with a much more refined and capable ECU. (I think the DPF would be binned if the map could be compenasated accordingly.)

I have now identified that I need a larger diameter Bosch MAF Sensor, the O/E is 4 pin 60 I.D. Air flow is maxed out at just over 172g/s. Bosch 0 281 002 437. Also a 3 bar or more Bosch map sensor, again four plug. The existing is maxed out at 255kPaA so I guess that is a 2.5 bar MAP Sensor. Bosch 0 281 002 437. Finding suitable replacements to swap over may not be easy so if anyone has knowledge in this are any information will be well received. The 3 bar map sensor and bigger MAF Sensor should allow me to fuel and run at 1.9 BAR which for a deisle is not that high a figure.

dan83590

If you had to compare a tuned diesel to a similar powered tuned petrol vehicle what would you say? Any pro's and con's for each method Harv?

prodriverules

iTrader: (52)

love the torque,love the fuel consumption for power but hate the short power band on all theses modern day derv's.

mickeymouse

I'm following this with interest, I will be getting same car (although in estate form) hopefully very shortly. Please keep posting what your doing...

That's a very impressive figure, the most I've seen so far from the 1.9cdti 150. Is around 220 bhp.

Good luck!

chrispy200+

iTrader: (2)

I've got a signum 1.9 cdti 120, it's dpf equipped and it's a pain along with the egr, trying to find a way of removing it, does the software your using to map the car have the potential to remove it?

harvey

iTrader: (48)

Dan: To take this from 150/236 to 230/335 has cost relatively little money compared to tuning a WRX or STi by the same percentage. Also, the logic of tuning a diesel is different to that of tuning a petrol. The down side is that with the current power level the car has to be driven with respect on wet roads in lower gears and on rough surfaces in 1st, 2nd and 3rd. However, the car has 6 well spaced gears and will pull from 1500 rpm. I rarely go to the red line as there is no benefit holding on past about 4300 but the red line is 5000. Because of the gear spacing which is much longer than you would associate in a Subaru you are not limited by a narrow rev band which is not actually narrow but only slightly less than the power band of most Subarus. You may have noticed it is not worth screwing the last 1000 rpm even out of most tuned Subarus and they don't pull much below 2700 rpm depending on model.
An LSD will be about £600 but having run an LSD on a tuned Astra 16v GTE I am not sure there is a lot of point for this car which the Wife uses to get to work and I borrow for trips down the country where 50 mpg plus and load carrying capacity is very welcome (plus an odd bit of fun locally). BMW Z3, Mini Cooper, boy racers and so on may not understand why their cars are so slow
The car was bought second hand MY06 for not a lot of money, 5 door, otherwise it would have been an estate and as I have said above there may be more to come out of cars with the DPF because of the more capable ECU.
I think at the beginning adding 35-40 bhp and getting it close to 300 ft.lbs cost £100
I don't know how a 120 will react as my experience so far is strictly limited to the Vectra 150 CDTi SRi. Speaking to the local Vauxhall dealer and he looks at you like someone with two heads when you enquire about an 80mm MAF sensor or 3 bar MAP sensor and the local Vauxhall specialists don't have tuning knowledge so that is where I am stuck at present. Basically a lack of knowledge.
I have had three attempts at removing the EGR, the last one being yesterday and I have given up on that. I know it is easy to do on VAG 1.9 and 2 litre but the GM system is slightly different. I made a very neat blanking plate and did all sorts of other work but so far I have been unable to delete the EGR without having one or other CEL. As the EGR only works at low revs I am not sure there are gains to be had and I have been unable to measure any gains in testing so I will now leave that well alone. I did replace the inlet manifold at an early stage £150 for a new one. Sod of a job. Thanks Darren. This has eight ports with four ports controlled by tumbler flaps. A common fault is that they sieze up with oil and carbon. Having examined the design carefully I am considering porting what is now a spare inlet manifold and deleting the tumbler flaps but it is a big job to swap the inlet manifold and I don't want to spend all day on it to fit a modified manifold to find that bottom end response has suffered. Getting more top end is not the ultimate objective. I guess another 20 bhp just for a headline figure would not be difficult but it would spoil the car.
If anybody wants specific knowledge I am happy to cover what I have done in detail just PM me with your phone number and I will get back to you when it is convenient.

harvey

iTrader: (48)

I have been told a BMW 530D turbo is the one to go for but on looking at a friends 530D I think that getting it to fit will be a job and a half. Apart from that they are only 230 bhp turbos. So I have looked at a few other turbos and think I need to stick with Vacum operated VNT as we want it spooling below 1500 rpm.

TonyBurns

iTrader: (3)

Harvey, the early 120's which are the 16v models (astra's) will react the same as your 150 model, the 8v ones will be more limited (good job I have a 16v 120 astra )

Tony