Intercooler Locations?

[Greenys_meanies 0]

Hi, i have a Turbo diesel ( yuck i know but mileage dictates) and it needs an intercooler as 1.3 bar is gonna kill it at some point!

I don't really want to go down the 306 top intercooler route as i would need an auto bonnent with a vent and i don't like the vent thing.

Where can i put a front mounted intercooler and what would be the best intercooler to use, needs to take at least 1.5 bar?

Where do the petrol turbo boys put theirs?

[DrSeuss 0]

behind the grille with a lowered rad is a popular option. Or in front of the rad being the other.

[Greenys_meanies 0]

behind the grille with a lowered rad is a popular option. Or in front of the rad being the other.

 

Has anyone got any photos please?

Any suggestions on good donor intercoolers?

[tom_m 0]

2wd/4wd cossie ICs fit above a lowered rad, behind the grill. if you run a search there are pics of a couple of 2ltr turbos with ICs in this location.

[Greenys_meanies 0]

2wd/4wd cossie ICs fit above a lowered rad, behind the grill. if you run a search there are pics of a couple of 2ltr turbos with ICs in this location.

Thanks found some. Whats the difference between a 2wd and 4wd cossie intercooler?

[V1 RDE 0]

 

Thats how mine is mounted. 4WD I/C is thicker than the 2WD. Almost twice as thick.

[Greenys_meanies 0]

Nice Photo Thx.

 

Is that a 2 or 4wd cooler?

 

Any advantage of using a 4wd intercooler?

[Alex G 0]

this is a 4wd intercooler. slightly more snugg.

4wd is better, but im sure the arguments depends on how much boost youre running. at 1.5 bar id personnally go for as big an intercooler as you can

 

Edited February 16, 2006 by Alex G

[Greenys_meanies 0]

Nice photo, is there any problems i should look out for when lowering the radiator for the intercooler?

[Greenys_meanies 0]

Also is it a big job? will i need anything apart from metal?

[Alex G 0]

You just need metal, a welder and an angle grinder.

Just make sure the front valance covers the radiater, so dont put it too low.

 

Only bad thing about doing it this way is you loose alot of stiffness at the front, (not that it will affect handling as the engine stiffens up the front) but you may have to reinforce the slam pannel because the rad cowling stiffens it up alot. if you dont you may have trouble closing the bonnet.

 

oh, and i had to cut off the safety catch to clear the intercooler

[TEKNOPUG 3]

You just need metal, a welder and an angle grinder.

Just make sure the front valance covers the radiater, so dont put it too low.

 

Only bad thing about doing it this way is you loose alot of stiffness at the front, (not that it will affect handling as the engine stiffens up the front) but you may have to reinforce the slam pannel because the rad cowling stiffens it up alot. if you dont you may have trouble closing the bonnet.

 

oh, and i had to cut off the safety catch to clear the intercooler

 

 

Will the 4WD I/C fit beneath the Rad, or did you just fit it above for aesthetic reasons?

 

The 2WD should suffice for most applications.

[Alex G 0]

i thought it would be more awkward to get the boost pipes to the intercooler if it was below, and hence i chose to mount it on top, so i guess it saves money on boost pipes! Dont quote me on this but i think fuqa put his below. (i dont think the 4x4 will fit below but the 2wd does)

 

this is what it looked like when finished, so it wasnt really for aesthetic reasons.

 

 

a true sleeper

Edited February 17, 2006 by Alex G

[sonofsam 5]

Think i mayave gone a bit OTT

 

O well its there if i want to run big boost later

im going to hide those pipes beneath a Pug Performance Evo valance

PM me if you need some steel or ali offcuts

[Dj_mini 7]

Do you not think that all thoes 90deg bends are going to reduce flow rate? As i didnt realise how much diffrence it makes untill i installed mine in my saxo with far to many bends then i got told that every 90deg bend reduces flow by 10% it mayed my car have a big lag problem. You want to try and make the distance between the turbo and inlet as short as poss with as few sharp bends as poss.

[sonofsam 5]

Do you not think that all thoes 90deg bends are going to reduce flow rate? As i didnt realise how much diffrence it makes untill i installed mine in my saxo with far to many bends then i got told that every 90deg bend reduces flow by 10% it mayed my car have a big lag problem. You want to try and make the distance between the turbo and inlet as short as poss with as few sharp bends as poss.

 

Cheers for the advce.Yes i have considered it.did'nt realise it would affect it that much!! Alwys assumed it was the bigger the turbo the more lag you got.(sorry new to this).I may get the IC re-welded to have the inlet/outlet on the back thinking about it,that should cut out the 180's..not to worried about the 90's though.

[Dj_mini 7]

I didnt realise it would think it would be a prob either so i jumped in head first as per normal got it all on there ended up with five 90deg bends in the pipe work put it this way it didnt work to well!

[TEKNOPUG 3]

It's not quite as bad as it seems. You'll only notice once you've been off the throttle for a while (like in traffic). It's no worse athan having lots of extra length to get over the 90deg problems.

 

If you look at a lot of super cars (Porsche 959, Ferrari F40 etc) you'll see thar they all have bends in their boost systems.

[Guest taylorsturbo345]

hi,

sorry to hi-jack somebody else question,

 

can some people send in pictures of how they have done the pipe work, like a picture of the engine bay. i've lowered my rad today but not sure how to change intercooler pipes because there are smaller beather pipes that come off the big pipe.

cheers

[Greenys_meanies 0]

hi,

sorry to hi-jack somebody else question,

 

can some people send in pictures of how they have done the pipe work, like a picture of the engine bay. i've lowered my rad today but not sure how to change intercooler pipes because there are smaller beather pipes that come off the big pipe.

cheers

 

yep some pictures of pipework will be handy.

 

which is better a cossie intercooler with the pipes over the top or a tt style intercooler with one pipe underneath?

[DTORU 0 1 Cars]

The only intercooler i found that would fit a 205 td is the 306 td top mounted setup, straight fit no mods needed with the exeption of needing the 306 camshaft and vacume pump for the brakes. for a front moounted one i trying to make i have a inlet manifold of a citroen xantia 1.9th and all the pipe work and the intercooler its self although its far to big to fit in the 205, wont fit between the light! doh.

 

im running 24psi of boost and i have maxed the fueling as much as it will go. the engine runs fine and the engine temp is what it is when stock even after a dam good thrashing. Dont up the boost on a not intercooled motor as i have done this befoe fitting mine and then engine temp goes off the scale with in a few seconds of boosting.

 

Dont know the power yet but its quicker on acceration that a fiesta zetec si and about the same top end.

the old girl driving thought i had a 1.9 gti fitted but when i told her it was a diesel she went bright red, lol.

[24seven 104]

top mount with a pulsar GTI-R vent .

 

[Greenys_meanies 0]

Can't believe you put a nova on this site with bolt on bits! oh didn't the nova only come with bolt on bits? lol

Nice idea but i like the standard look. FMIC me thinks

 

The only intercooler i found that would fit a 205 td is the 306 td top mounted setup, straight fit no mods needed with the exeption of needing the 306 camshaft and vacume pump for the brakes. for a front moounted one i trying to make i have a inlet manifold of a citroen xantia 1.9th and all the pipe work and the intercooler its self although its far to big to fit in the 205, wont fit between the light! doh.

 

im running 24psi of boost and i have maxed the fueling as much as it will go. the engine runs fine and the engine temp is what it is when stock even after a dam good thrashing. Dont up the boost on a not intercooled motor as i have done this befoe fitting mine and then engine temp goes off the scale with in a few seconds of boosting.

 

Dont know the power yet but its quicker on acceration that a fiesta zetec si and about the same top end.

the old girl driving thought i had a 1.9 gti fitted but when i told her it was a diesel she went bright red, lol.

mine boosts fine at 1.3bar no intercooler, though you do notice the power dropping off as it starts to get rather warm! can't wait to fit the cossie I/C

[DTORU 0 1 Cars]

Im finaly going for a escort rst hybrid intercooler that will fit under and infront of the rad. Want to run 30psi of boost when i get it done. lots to do before that though, new bearings and rod bolts etc.

 

looking for about 150bhp-170bhp when done.

[Greenys_meanies 0]

Im finaly going for a escort rst hybrid intercooler that will fit under and infront of the rad. Want to run 30psi of boost when i get it done. lots to do before that though, new bearings and rod bolts etc.

 

looking for about 150bhp-170bhp when done.

What engine are u using? thought about the 2.2 HDi ? 136 bhp as standard