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200Tdi: questions about EGT


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Hi guys,

I hope you are all doing well during these challenging days.

I am new to this forum, but have been a rover enthusiast for ages. My current rover is a 1989 range rover converted to a 200tdi. I have gone through an exhaustive process of tuning the FIP noting every change and recording the resulting data, both qualitative and quantitative. I would like to post my method soon, when I have a little bit of time, because maybe it will be useful to those who need to start over without any reference to the factory settings. My FIP was not original, as it was obviously from a 300Tdi with provisions for the EGR fitment. The anti-tamper collar and plug were previously removed and the diaphragm had already been adjusted and it was a bit of a dog. Anyway, I worked through a process to tune the FIP from scratch, based on the fundamentals of each adjustment and it seems to be running powerfully and efficiently without any smoke issues. If there is interest I will post my method.

As to my question of EGTs, it is well documented that ~730  C is a hard maximum for sustained temperatures in the 200/300Tdi, with some scattered anecdotes of people running much higher. The main factor for this limit is usually linked to damage to turbine vanes. My question is, does anyone have reliable knowledge about the safe limits of the other engine components, such as the head and pistons? I have an aftermarket Billet Hybrid Turbo Turbocharger CHRA, from Turbo Rebuild Ltd, for which they recommend a maximum safe limit of 850 C (1562 F) and I am wondering how much I can safely, if at all, push the rest of the engine beyond 730 C. Currently, my engine is pulling hard up to ~4000 RPM at 16 PSI of boost, but the EGTs rise quickly during hard acceleration and will easily exceed 1400 C on a steep incline . I know I can get a few more PSI out of the turbo (maximum recommended 22 PSI) which will reduce EGTs, but right now I am unwilling to go beyond 18 or 19 PSI, as I do not know the history of the engine or the condition of the head gasket. At the moment I can easily moderate the temps with my foot, and keep it between 1200 and 1350 when pushing it hard on the highway, especially while overtaking vehicles or climbing hills. I like having the extra power when I need it, but I also want to be able to keep my eyes on the road during those times rather than down on my poorly located gauge.  

I plan on refining the FIP settings to get the temps down a little more, but I hope to keep the level of performance where it currently is.


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