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 The ZT/75 CDTi Intake Mods- All you ever wanted to know. 
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 Post subject: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Sun Oct 07, 2007 4:14 pm 
Rovertech Kiloposter

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Well as most of you know when tuning the CDT/CDTi engine the problem is getting enough air into the engine as the fuel pump has more than enough capacity to supply fuel for well over 180 BHP. There are various intake modifications that can be done for little or no money to improve the breathing of this engine. This is essential with any type of tuning be it a remap or a Rover Ron tuning box. The standard air intake was designed for 116BHP and to keep the car as quiet as possible. As can been seen below there isn't mush of a "hole" for the engine to breath through - it's very restrictive.
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Figure 1 - The standard air intake (Taken from Rover Rons Website)
The first modification was to open up this mouth but to reuse the original 3 fixings to keep it looking as standard as possible. It's important to inset a bolt into the middle of the opening - if you don't then the intake can suck it's self shut when accelerating!
Image
Figure 2 - the basic intake mod
This significantly improves breathing but can be improved upon further if you are willing to not look standard. This involves removing the flexi section which does appear to restrict flow a little.
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Figure 3 - The cut back intake mod
Another idea was to fabricate a intake as seen below
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Figure 4 - The Fabricated Intake
This did improve airflow but did not work as the rocking motion of the engine will, over time, crush and distort the intake. It also transmitted a lot of vibration from the engine to the that car body. Therefore this idea was abandoned.
So using the standard air intake, as shown in figure 3, this is as far as you can go - but there is another, and in my opinion, better route to take. This involves getting rid of the standard intake tube and using a piece of 76mm flexi ducting. This is available off Ebay for about £16.99 + P+P
http://cgi.ebay.co.uk/3-76mm-PIPERCROSS-K-N-AIR-INDUCTION-DUCTING-HOSE-1M_W0QQitemZ290166830016QQihZ019QQcategoryZ72205QQtcZphotoQQcmdZViewItem
I have been using this intake for a few weeks now and am very pleased with the results.
The ZT has an opening in the front of bumper that looks idea for a cold air feed.
Image
Figure 5 - ZT bumper showing location of cold air feed
This is an ideal place to pick up lots of cold air. Of course if you run thorugh a river or stream that is more than a 1ft deep you could pick up water and this would ruin the engine - some think to think about, you have been warned!!!
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Figure 6 - Close-up of ZT bumper showing location of cold air feed
A 1m section of 76mm ducting is sufficent and will fix directly onto the air filter housing as can be seen in figure 7 below. A large jubilee clip will keep the hose fixed to the housing.
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Figure 7 - Intake hose onto the Air filter Housing
Two cable ties are used to position the hose away from other hoses. This is essential as you don't want this to rub against a water hose and break it over time! I did try larger hose (90mm) but this is too large as there is simply not enough room in the engine bay.
The engine cover will re-fit but does require a little cutting in the area of the hose. This is a simple 5 min job.
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Figure 8 - Intake hose with engine cover
So there you have it, this is, in my opinion the best air intake to date. It appears to give more benefit in the mid range where resent testing has shown over 300lbft at 2500rpm. On the motorway at speed it's very noticable. Quicker pick up and almost no smoke - despite over 170 BHP. In the hot weather you could feel the benefit when standing in stational traffic - there was no heat sink effect.
I must state again that if you drive through water over 1 ft deep you will run the risk of damaging you engine so don't do it!!

It is also worth pointing out that you may need to cleam you MAF on a more regular basis, especially if still using the OEM Bosch MAF. I recommend doing this every 3 months anyway as part of regular maintenance to improve low down responce and ensure maximum MPG

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Last edited by Ti Rich on Wed Oct 10, 2007 10:20 am, edited 1 time in total.

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PostPosted: Tue Oct 09, 2007 7:30 pm 
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Where is the air filter located Rich?

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PostPosted: Tue Oct 09, 2007 7:50 pm 
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At the back of the engine, lift the plastic cover off, then look down bulkhead you'll spot it :)

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PostPosted: Tue Oct 09, 2007 8:10 pm 
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Richard

Regarding the FBH...

I THINK the pipe will come a bit further forward and exit under the 3" black intake pipe before descending into the bowels of the car, thus (hopefully) avoiding the FBH.

If the Post Office are kind enough to get their finger out tomorrow, I may well know by this time tomorrow evening ;)

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PostPosted: Tue Oct 09, 2007 9:30 pm 
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stickey this please

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PostPosted: Tue Oct 09, 2007 11:59 pm 
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What's FBH?

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PostPosted: Wed Oct 10, 2007 1:08 am 
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Leo wrote:
What's FBH?


Fuel burning heater, a webasto basically. It burns fuel to heat the coolant system on a cold morning. Means that cold start time is reduced (or when used as a parking heater removed all together) and that the cabin is warm much quicker.

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PostPosted: Wed Oct 10, 2007 7:12 am 
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al_roverMG wrote:
Leo wrote:
What's FBH?


Fuel burning heater, a webasto basically. It burns fuel to heat the coolant system on a cold morning. Means that cold start time is reduced (or when used as a parking heater removed all together) and that the cabin is warm much quicker.


Mmmm - Yes

Very nice it is too ;)

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PostPosted: Wed Oct 10, 2007 8:43 am 
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It's only for the older people...... :wink:

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PostPosted: Wed Oct 10, 2007 12:57 pm 
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Rich i am not old and i have one to be installed on my ZS.

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PostPosted: Wed Oct 10, 2007 1:10 pm 
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al_roverMG wrote:
Rich i am not old and i have one to be installed on my ZS.


I'm not old either and I already have one on my car :P

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PostPosted: Wed Oct 10, 2007 1:52 pm 
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Ah right yeah I've heard about those things before. Never heard that acronym though.

Paul, would I be right in assuming that your 75 had it fitted aftermarket rather than it being an OE part on all 75's?

Sorry for taking this off topic, I'm just curious :)

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PostPosted: Wed Oct 10, 2007 2:23 pm 
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Leo wrote:
Paul, would I be right in assuming that your 75 had it fitted aftermarket rather than it being an OE part on all 75's?

Sorry for taking this off topic, I'm just curious :)


No Leo - it was an OEM option for diesel engined 75 and ZT variants

The modification to make it remotely operated and to be able to heat the car interior was done as an aftermarket job though.

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PostPosted: Wed Oct 10, 2007 2:32 pm 
Rovertech Kiloposter

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I think the FBH was standard on the CDT until project drive.

PS - sorry about the "old" comment, i want one too.

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PostPosted: Wed Oct 10, 2007 4:03 pm 
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Ti Rich wrote:
I think the FBH was standard on the CDT until project drive.


Hmm - I have the options selection list for mine and it shows the FBH as a selected option. I wonder why

Ti Rich wrote:
PS - sorry about the "old" comment, i want one too.


That's OK Richard - I guess you're just 'Old at heart' :P

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PostPosted: Sun Oct 14, 2007 11:17 am 
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I'm old enough to have one
But haven't. :cry:


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PostPosted: Sun Oct 14, 2007 11:45 am 
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Johndotcom wrote:
I'm old enough to have one
But haven't. :cry:


Hello John :D

Welcome to Rovertech. It's a little different to 'The Club' ;)

I hope the links I sent you were of interest.

al_roverMG has an (as yet) un fitted FBH but I'm not sure whether he intends to fit it or not.

Can't hurt to ask.

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PostPosted: Sun Oct 14, 2007 11:49 am 
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Raistlin wrote:
Johndotcom wrote:
I'm old enough to have one
But haven't. :cry:


Hello John :D

Welcome to Rovertech. It's a little different to 'The Club' ;)

I hope the links I sent you were of interest.

al_roverMG has an (as yet) un fitted FBH but I'm not sure whether he intends to fit it or not.

Can't hurt to ask.


Nah he just stands around with his hands in his pockets! :lol: I do believe it's due to be fitted soon tho :)

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PostPosted: Sun Oct 14, 2007 5:20 pm 
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mach1rob wrote:
Nah he just stands around with his hands in his pockets! :lol: I do believe it's due to be fitted soon tho :)


Oi cheeky git. Yeah soon as funds allow it will be going on but the tapping fuel and coolant lines worries me a bit so gonna get the local fitter to do it for me. They are asking 200 quid for all the bis needed (pump wiring harness etc) and the conversion to a parking heater and fitting.

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PostPosted: Sun Dec 09, 2007 11:34 pm 
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NOTE:- The cold air feed method will NOT fit on automatic cars (sorry Paul). You may also have some difficultly if you have a FBH too.

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 Post subject: Re: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Sat Jun 21, 2008 3:48 pm 
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Would you notice the effects of this on a standard 115 engine? I plan to get a Synergy hopefully when funds allow!

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 Post subject: Re: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Sun Aug 28, 2016 5:23 pm 
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Great information and an insight will be sorting out my intake ( well opening it up ) smartish :thumbup:

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 Post subject: Re: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Sun Aug 28, 2016 6:44 pm 
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8 year old thread epic revival

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 Post subject: Re: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Mon Aug 29, 2016 9:06 am 
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Good revival :thumbup:

This information is now out of date. It had been discovered that the standard intake is more than adequate for power up to 160hp, which has been set as the safe limit of the drive train. I think it actually surpasses the max torque the auto gearbox is rated to, so little point trying to get more out of an auto, and the clutch becomes an issue on the manuals with the higher powers.
By modifying the intake, it's been said you upset the air flow and actually make it worse. If your looking for more power, get the 160 map. Couple of t4 gurus offering it and it transforms the car. No extra mods required.
Loads more info on the 75 zt forum


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 Post subject: Re: The ZT/75 CDTi Intake Mods- All you ever wanted to know.
PostPosted: Mon Aug 29, 2016 11:10 pm 
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it good to see people still looking through and using the Forum as it should be used Power to the RT Forum !! :thumbup:

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