Water-Intercooler installed (1 Viewer)

[-MaTTi-]

Fitting:

Pipe fitting:

The intake pipe "welded" by Techno-Weld (Techno-Weld) Not nice, but it´s tight:

Intake with homemade gas pedal cable holder:

The radiator, the water pump and the swirl tank:

The swirl tank:

Here it is, all installed:

The front view, I managed to get the radiator very close to the bumper hole:

But there was a lot of heat under the hood at slow speeds (in traffic hour) and at high speed too (120 km/h). My bull bar is blocking quite a lot the radiator hole in the front bumper.

So I install a fan (10") for the intercooler radiator.

I made this temperature controlled (it starts at +40C and shut down under +30C).


Parts needed:

-Air-to-Water intercooler, core size: 10"x4.5"x4.5"
-Radiator (Fiat Cinquecento)
-Water-circulalation pump (Bosch 0 392 020 064, 1200 liter/hour)
-Swirl tank 0,75 liter (homemade of aluminium drinking bottle)
-Expansion tank (VW Golf)
-76 mm/63 mm aluminium pipes
-76 mm to 51 mm 45° Silicone Reducer + 3" 90° bend
-19 mm hoses
-Clamps
-Brass fittings
-Wires+relay+switch
-10" fan +relay+temperature switch

It works very well, it feels more powerful and the torque is better too. 8)

Here is a dyno sheet (original motor gives 125 hp and 295 Nm):

This model is manufactured without intercooler, like all Toyotas with 1KZ-T(E) in Europe.
And those who think there is no space under the hood for this kind of device, I have 2" bodylift. It makes this project possible.

 

[matt.mcinnes]

Do you know you pre and post inter cooler temps?

 

[-MaTTi-]

Do you know you pre and post inter cooler temps?

I have only measured ones, when driving 120 km/h, boost 0.7 bar, ambient 22°C, pre was 97°C and post was 60°C. Not good at all. The cooler was very hot.

So, I add a 10" fan. I think it´s much better now. I have to take more measurements.

P.S. Your water-ic looks very nice! And the rest of the project too.

Edit: I measured post-intercooler temperature with the fan, it´s about 30-35°C at normal cruising 80-100 km/h and rised to 46°C at 120 km/h. Ambient temperature was about 15°C. I only have one termometer, so I didn´t took pre-intercooler temp at this time.

 

[marin]

What is the swirl tank for?

marin

 

[-MaTTi-]

What is the swirl tank for?

marin

In my case, just for increasing water capasity of the system. It´s made of an aluminium drinking bottle (0,75 liter).

 

[marin]

oh ok, you made it sound more technical calling it a swirl tank, which is why i asked. lol.

marin