Defender Upgrades: Td5 Engine

Stage 1 and Stage 2: What do they mean?

Every company out there will have a different version of the same basic principles, though here at Pangaea, we tend to keep things simple and offer either a Stage 1 or Stage 2 performance upgrade. Some companies will offer up to ‘Stage 4’, but in reality, this would be the same as our Stage 2, as there is very little more to offer than this.

Stage 1

For us, a Stage 1 upgrade is simply an ECU tune. A factory delivered Td5 engine wasn't tuned for performance and has a lot of untapped potential which can be easily exploited through a simple remap. All our ECU tunes are supplied by Alive Tuning in the UK, who are the go to Td5 specialist. A factory delivered Td5 has around 122 hp and 300Nm of torque  and these numbers will typically increase to around 160hp and 370Nm, a fairly considerable 30%+ increase in power and 20%+ increase in torque. It’s worth noting that these figures may seem fairly conservative compared to other numbers seen online, but in reality, this is the highest safe performance level that should be achieved without upgrading any mechanical parts. 

Stage 2

A Stage 2 upgrade is much more than a simple ECU tune and will see performance figures increase to around 210+hp and 450+Nm, or around 70% increase in power and 50% increase in torque. Fairly substantial gains and one that will have a dramatic improvement of the performance and driveability of the Defender. 

To reliably exceed the performance figures of a stage one ECU tune, many major mechanical components will need to be replaced. Whilst others may offer similar power upgrades, it’s important to understand the limitations of these components in order to safely and reliably increase the performance. 

Whilst the list below isn’t exhaustive, it will give you a good understanding of the components that will be upgraded. Changing all the components below is no small task and comes with a significant cost, but in our experience, it is the only way anything other than a basic Stage 1 ECU tune should be done.

Turbocharger

Whilst the factory turbo is a good design, reliably achieving more power really requires a larger turbo. We fit a GTB450 Turbo from Alive Tuning, which is substantially larger than the factory turbo, but bigger isn’t always better. It’s designed to provide massive torque at low rpm and they really make a Defender move rather quickly!  

Exhaust System

A larger diameter exhaust system allows the expulsion of more exhaust gases and heat away from the engine which comes with the increase in power. Essential at maintaining sensible Exhaust Gas Temperatures (EGTs). We’d recommend a 2.5 inch stainless steel system for optimal performance, and going much larger can have a negative effect.

Intercooler

A standard intercooler on the Defender is fine for a Stage 1 ECU tune, but fitting a larger, more efficient and stronger intercooler allows the engine to feed more colder air to the larger turbocharger and improves the density of the air entering the engine, resulting in better combustion and, ultimately, more power. This modification also helps maintain efficiency, as cooler air requires less fuel to achieve optimal combustion.

Inlet and Boost Hoses

With the increase in boost pressure comes the need for stronger hoses to deliver this fresh air. These silicone hoses are much stronger than the original rubber hoses, and the inlet hose is reinforced so that it won’t collapse under vacuum. 

Clutch

A heavy duty performance clutch is essential when running a Stage 2 upgrade to carry this additional power and torque to the drivetrain. Whilst the OEM Valeo clutch that we would fit to a standard or Stage 1 vehicle is very good, they simply wouldn’t cope with the additional performance.

Air Filter

One of the cheaper upgrades, a free flowing performance air filter does exactly what it suggests, allowing more air to pass through it. With a Stage 2 upgrade it’s also not recommended to fit snorkels as these will restrict the air flow. 

10p vs 15p

It's worth noting that there are two variants of the Td5 engine, the earlier 10p which was used when the Td5 was introduced up until 2002, and the 15p which was used from 2002 onwards. Whilst the engines are almost identical, one major difference for the purpose of tuning only, is the ECU’s. In order to remap an earlier 10p ECU, the chip itself must be removed from the circuit board, a task to be carried out by a specialist. The later 15p can simply be plugged in through the Defender’s OBD plug next to the cubby box or middle front seat. 15p ECU’s can be programmed and fitted to earlier 10p engines, but not the other way around.

Final Thoughts

The Td5 engine is a superb engine and one that additional power can very easily be unlocked with a basic ECU tune. Upgrading things further with a Stage 2 upgrade will transform the Defender into a vehicle that you didn’t know it could be! Whilst the cost increase is substantial, change in vehicle characteristics and the improvements to the drivetrain are beyond substantial!