MAX power on TDCI 2.0 focus 2012

[Executer]

Hi all,

Just wanting some opinions/ideas in regards to increasing the power output of these babies. I know a decent tune can get it to something like 152kw and 440nm of torque on a stock motor.

The mods I'm planning on doing to mine are: k&n filter, turbo back exhaust, dyno tune.

Does doing a good dyno tune up the boost on the turbo?

I would like to know if there are any other turbo diesel mods available. Ideally it would be nice to get the kw figure up around the 180 mark.

Would like to know what youve done to your car and where the increase was felt most.

Cheers

[Yellow_Festiva]

180kw is a huge jump in power. I think the diesel injectors are the hold up to more power. If you want 180kw and 440+nm is there a larger capacity engine from the same family that can bolt in with minimal mods?

[Stugots]

Sounds like you should take the TDCi back to the dealer and look for a good trade in on an ST when one becomes available.

[Russ]

I think it would be quite possible to achieve 180 KW but it will cost big $$$ to achieve and then you will have to consider the extra strain that will put on other components as well, such as the driveline etc.... If you really want those sort of KW's you should probably have considered a turbo petrol engine before buying the diesel

[Executer]

Originally Posted by Stugots

Sounds like you should take the TDCi back to the dealer and look for a good trade in on an ST when one becomes available.

I love this car. Just curious to see the max it could make. I'd be happy with a good dyno tune and good air setup and maybe better intercooler if needed.

I wonder how well it could compete with a stock ST after a good dyno tune. The torque figures would be nice.

[Turbodiesel]

I've kept up with, and overtaken modified XR5s around Marulan. I was probably the only car that could leave it in 3rd around the whole track.

It'll never be as good off the line but pretty close on a rolling start.

[Franco Cozzo]

Air intake does not give a much gain on this car, as the original intake pulls cool air in from above the passenger side wheel (outside of the engine bay) - well it does on the UK version. It does look restrictive but I’m not sure it actually makes much difference. Also the intake piping on the ST is different, it is only the intercooler which is the same.

I did some testing with a few different filters on a dyno and the k&n 57i kit was the worse, it was down on power everywhere compared to the standard system with a new paper filter. (bonnet was open all the runs) I don’t think there is an enclosed kit for sale from k&n.

I ended up using a very big twin cone filter, inside a homemade box with no lid, just flexi sides so when the bonnet is shut the under bonnet sound proofing closes the box, with a cold air feeds which keeps temps 1-2 C above ambient and temp doesn’t sore up when at a stand still.


Below is for who ever is interested in my continuing pain of tuning one of these..... before i start ill say i have learnt this engine is not the best for tuning mainly due to engine sensors not having a wide enough range, limitataions of the stock injection system, limitations within the injector duration mapping, big low down torque is going to cut down the life of the DMF and no single mass flywheels are availble (within reasonable costs), i cannot find anyone for is willing to modify siemens common rail injectors so as far as i can see we are stuck with standard injectors and there low flow potential.

The below has been slowing done over 4/5 yrs and 110K on the engine.

1- Even with a remap the clutch will need to be replaced sooner or later, could stick with a standard one but it wont last as long as it should. DMF (which is expensive) will probably need changing at the same time for the new clutch to bed in on

2- Decat, de-dpf, exhaust mods – not going to give you a lot, but you will gain. However not until the car is mapped to the mods. I lost peak power when I installed my decat due to the extra airflow was not match by increased fuel.

3- Intercooler – if your not planning to increase the boost then the standard one is fine, I have airtech Gen 3 - can post a comparison pic if you want.

4- Hybrid turbo – the GT1749 can have the 49mm compressor wheel replaced with a 52mm one (but make sure it’s the right 52mm compressor wheel ie the biggest available) think it is 436131-0002. As there are 10+ different 52mm wheels, you want the deepest one with the biggest tips to the fins – as this will flow the most. With this 1.8bar is about the limit before turning into a hair dryer. Mine cost me £440, but i had a spare turbo.

5- Boost – push the boost above 1.45 bar (with the hybrid) and you will need a Fuel Cut Defender as the standard MAP (Manifold Absolute Pressure) sensor can only read up 1.5 bar, if boost slips above this then ecu cuts the fuel and your progress in dramatic style. With a FCD installed you will be running boost blind (ie ecu can’t see it) so has to be very well controlled within the fuel mapping and you should be running a boost gauge. Ideally you would want to install a 3 bar map sensor (like the VAG boys do) but the MAP sensor maps aren’t available and I don’t know anyone who can remap the car with a different MAP sensor installed. Paul @ RSTuning said he couldn’t do it without the correct information.

6- Injection system – it’s a crap Siemens system. Wish ford had installed a bosch system as in the PSA 2.2 tdci with 175hp (and the latest with 200hp). As this 2.2 is basically the same as engine lump as the 2.0 but with an increase stoke. From what I know the Bosch injection pump / injectors from 2.2 are not compatible with the our ECU.

The the main change between the 136 and the newer 2.0 with 163hp is that it has moved to a bosch injection system, but I believe is not reserve compatible due to our injectors being siemans piezo-electric and the 163hp injector are bosch solenoid injectors.

So at the moment i have the hybrid turbo to flow more than enough air, but the injection system cannot flow enough fuel quick enough* to get full use of the all the extra air Due to this there is not much point in fitting a hybrid turbo

*the injector durations are having to be widened to get some extra fuel in(since cannot push CR pressure up anymore due to pushing another sensor out of it limits), but this gives less time to burn the fuel = smoke at high revs on full throttle. And due to this its cutting fuel from 4K to manage some of the smoke.

It would be better if i could fit some bigger nozzles on the standard injectors - to flow more fuel in a shorter injection duration. But need to find someone you can modify Siemens injectors. Last run at RST on my 117K 2.0tdci developed 300-310ft/lb (1900-3100rpm) and a flat ~184hp from 3250-4000. Has probably lost some ponies due to the miles.


Mine does hold the peak power for alot longer than most dyno graphs of these engines, normally peak for only a couple of 100rpms around 3.8K, for those who dont know the RST dyno is know for being a ball breaker, ie not an overestimate like many other places. I liked what Paul said to me last time "if you want more power, get it dyno'ed somewhere else"

I'm not planning getting rid of the car, as i can do everything but the gearbox stuff and it's still not using any oil between services and i want to see how many miles i can get out of it. If it does go bang then i've got an excuse for a bmw diesel.

The bolded part with the air intake doesn't apply to me in particular as our LVs have a different air intake setup.

His dyno graph:



I was talking to a tuning company in London who said they know a place which can high flow the injectors on these cars, but at $920 each from Ford, its a costly mistake if it goes pear shaped, when I asked my mate who works at Ford he said there are 4 different injectors listed for these 2.0 TDCIs so maybe there were a few revisions.

Diesel is pretty amazing but I think we chose the wrong one to modify, its really the siemens injection side of things which is holding us back.

I'm waiting on tax back money then mine is probably going in for the tune and intercooler fitment.

[Executer]

Thanks for the help mate. like ?I said, im new to the diesel scene but loving it.

[Executer]

yep. I'm leaning towards a new air filter ( just for the sake of it ) and a good dyno tune. The car goes well, just be nice to have a little extra. Will keep my eyes peeled on the R&D of Dielsel performance.

[Franco Cozzo]

Originally Posted by Executer

yep. I'm leaning towards a new air filter ( just for the sake of it ) and a good dyno tune. The car goes well, just be nice to have a little extra. Will keep my eyes peeled on the R&D of Dielsel performance.

[Executer]

Gee, thanks mate. lol . Might get a blow off valve for the sake of it too

[Executer]

Might speak to a place that specialise in diesel tuning. Curious about port polish of the throttlebody.