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mattlab

Member Since: 16 May 2011
Location: suffolk
Posts: 143

2009 Defender 110 Puma 2.4 USW Galway Green

BAS REMAP, INTERCOOLER AND ALIVE EXHAUST

Well i`ve been wanting to tune my defender for a couple of years now, So after a fair bit of research and umming and arring i settled on a Bas remap, Alisport intercooler and Alive stainless exhaust from the cat back.
So, first off i set about stripping the old intercooler out, No dramas there and actualy more room than i thought the`d be, So,Iin with the new cooler,

it wont fit, Find out one of the pins welded on the new cooler that fits in holes on the radiator bracket is slightly in the wrong place,
After taking the cooler in and out a few times in order to discover this problem i took the round file to the radiator plastic brackets and filed a few mm from the holes.
Cooler back in, Sorted.
Front end back together

Now for the remap, Read the original file, Sent off to Pete, Received new file back, Uploaded on to ecu now off for a test drive. Now, Several years ago i had done similar to a TD5 90 and the "tuning box" i put on it turned it into an absolute animal, So much so that i changed to disco gearing because 1st gear was unusable and even after the gearing change it would still scrap all four tyres when hammering it round a roundabout,Yes it did smoke and ive no idea what the box was doing to the engine, But hell it was fun !!!
so, first impressions as i drove off nice and steady was that i did`nt have the map on, after getting on the open road i soon realized that yes it was on, the power didn`t come in as low as i thought it would (as it had on the 90) but it is a different engine and a more refined map.
So after several miles playing about with my new found power, Overtaking cars willie nillie and generally hooning about overall i was happy.
After getting back home i phoned pete to ask about the power not really coming in till about 1600-1800 revs,
he said he can make it come in lower but id soon be ringing up complaining of excess smoke, Good point i said, That`ll do me.
Now for the exhaust, Called gary at alive and had a good chat with him and ended up ordering a full system including the decat.
Whilst sitting and waiting for said parcel to turn up i went on you tube to see what a full system sounded like,
found a few and instantly decided i did`nt like the turbo sound with the decat pipe (sounded a bit too much like a dump valve going off when changing gear, That all too many boy racers have)

, Back on the phone, Cancel the decat.
Rest of exhaust arrived the next day, Keen to get it fitted and like an excited small child at xmas the following days work was cancelled (the joys of being self employed)
Removed to old center box (bloody hell thats heavy) and rear box and fitted the new mid section which has a small inline silencer and the tail section with no silencer.
Had to bend down the rear mounting bracket on the truck as the new pipe was just rattling on the rear x member, But apart from that the new exhaust is very well made and looks very pretty

Now, i only use the truck at weekends and then not every one so most of the time it just sits on the drive making me smile everytime i see it. I had a couple of trips to hampshire planned so i thought id give it a few runs before i posted this review on here.
To start with i had quite bad injector rattle at about 2000 revs with netreal throttle, But knowing how my transit is whenever i have anything done to the injectors, It takes a few starting seqences for it to settle down.
And thats exactly whats happened, Have now done about 700 miles with new parts fitted, Engine is quiet with a lovely amount of mid range power as it should be from the factory, Being able to fly up slip roads and not only match the traffics speed but be faster than them does bring some raised eyebrows from other drivers,
Overtaking cars without having to plan your overtake like your driving an old 1600 diesel escort van is great fun,
exhaust note is superb (i have stood while a mate has driven it by) sounds no different under normal load but growls nicely when given some welly and no more smoke than normal.
Also no droaning on the motorway and i have no extra insulation in the truck (less in fact as i`ve removed the carpets and just have rubber mats)
Havent checked on the mpg as yet but then you dont get more power and then dont use it so i can safely say my mpg is worse

All in all im very happy with how my upgrades have turned out and im very glad ive done it.
Big thanks to Pete at bas for the map and intercooler and another big thanks to Gary at alive for the long chat and superb exhaust

LIFE`S TOO SHORT TO DRIVE A BORING VEHICLE

Last edited by mattlab on 10th Aug 2014 3:54pm. Edited 1 time in total

9th Aug 2014 6:17pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348

Do you have any photos of the exhaust?

9th Aug 2014 6:31pm

mattlab

Member Since: 16 May 2011
Location: suffolk
Posts: 143

indeed sir, i have

Click image to enlarge

Click image to enlarge LIFE`S TOO SHORT TO DRIVE A BORING VEHICLE

9th Aug 2014 6:47pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348

Very nice.

Would you say there was more of a growl / deeper exhaust note now?

9th Aug 2014 7:50pm

newhue

Member Since: 28 Apr 2014
Location: Brisbane
Posts: 351

The out of whack intercooler.
Did you seat the cooler properly on its lower rubber mounts. Initially I thought things didn't line up, and after the second fit up realised that one rubber foot was not in it position so hence the welded pins on the middle of the cooler didn't line up. So after a third fit it all went in exactly where it should.

Open up that air box a bit and it also seems to make it happy. Can only talk via seat of the pants experience, and it is minimal, could even be the placebo effect, but it seems to run that little bit better again.

Capitals also makes reading a whole lot easier. My Defender and travels

9th Aug 2014 8:36pm

And1145

Member Since: 04 Sep 2013
Location: Howden
Posts: 30

2011 Defender 110 Puma 2.4 CSW Buckingham Blue

I had exactly the same problem with the intercooler. One of the pins did not line up at all to drop into the radiator mounting hole. I chose to cut the pin off the intercooler, drill a hole in the mount and bolt it.

10th Aug 2014 11:40am

Lambley

Member Since: 20 Apr 2013
Location: Mid Devon
Posts: 1435

^^^ Similar problem as mine when I fitted a larger intercooler, the two strengthening bars that go at 45 degrees needed a trim to allow for the extra width, it didn't take long though.
I'd like to know more about the exhaust if you have time, what do you think of it? Is it a nice tone compared to the std one? Roughly what was the cost and can I get one for a Td5?

10th Aug 2014 1:40pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5697

2006 Defender 110 Td5 USW Zermatt Silver

The alive td5 exhaust is the fantastic. I miss it sooo much. I had the one with the cherry bomb Center box so no resonance inside. Wish you could get the same sound from a Tdci.

Andy.

10th Aug 2014 3:26pm

mattlab

Member Since: 16 May 2011
Location: suffolk
Posts: 143

Yes more of a deeper growl/raspy sound now, Also notice the difference regards a little more power, cant really hear it whilst driving unless you go through a tunnel or built up area, But i did stand by the side of the road as my mate drove by several times and yes, It does sound nice, not over the top.But not as nice as a TD5 with the same.
And i reckon the whole system weighs less than the center box alone !!! LIFE`S TOO SHORT TO DRIVE A BORING VEHICLE

10th Aug 2014 3:47pm

mattlab

Member Since: 16 May 2011
Location: suffolk
Posts: 143

Abbreviation sorted

LIFE`S TOO SHORT TO DRIVE A BORING VEHICLE

10th Aug 2014 3:55pm

Alive Tuning

Member Since: 01 Mar 2010
Location: Louth
Posts: 609

Thanks for the kind words about our exhaust system.

Just a shame you never took an alive remap, with more low end torque as standard, and our ultimate Intercooler, which fits and performs flawlessly. Following the flock is not always the best choice!

Kind Regards,

Gary.

10th Aug 2014 8:27pm

newhue

Member Since: 28 Apr 2014
Location: Brisbane
Posts: 351

ahhh but Gary, some times the sheep follow for a reason.

That exhaust looks stainless, looks like some nose work also. Do you do it in standard exhaust type material however. My Defender and travels

10th Aug 2014 9:20pm

Alive Tuning

Member Since: 01 Mar 2010
Location: Louth
Posts: 609

Of course everyone follows for a reason. My point is regarding how well informed/misinformed people are about other options that are available for tuning.

Our sports exhausts are all made from 304 grade stainless steel, the material of choice for high quality aftermarket exhausts. The original Land Rover exhaust is made from 409 grade stainless steel, using mild steel flanges, so more prone to corrosion.

10th Aug 2014 10:29pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20348

The flanges certainly do rust.
Is there a full system including CAT?
Any would samples of the exhaust note Gary?

10th Aug 2014 10:50pm

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