intercooler installation tips ? - Page 2

Mickldo · 03-17-06, 03:56 AM

Quote:

Originally Posted by dieselcruiserhead

I can't say for sure because I have never messed around wtih them but a guy on the Cummins 4Bt list went to cummins and mapped out his engine with tire size gears computer etc and given the wieght of his truck the intercooler actualkly slowed things down plus added turbo lag etc. antoher guy bypassed the intercooler he put in and same thing, more performance without the intercooler. So that is my $.02 on it. I think that is perhaps why Toyota didn't install them in any diesel cruisers as far as I know. Also one more thing to break. that said I have one but only because my engine came designed for one so it was harder to not run it.. You might try plumbing it and seeing if it makes a difference but make any chances temporary until you know it works IMO...

Toyota does have intercooled turbo diesels. The 100 series turbo diesel has one. The Land Cruiser Prado turbo diesel has one.
Intercoolers do work they just need to be set up right. The intercooler has to be the correct size for the job. One of the reasons top mounts are used is to reduce the length of plumbing between the turbo and intake valve to reduce turbo lag(as opposed to a front mount).

Tapage · 03-17-06, 08:58 AM

a turbo setup with an intercooler, provides aprox 20 - 30 HP more ( it depends on apliocation ) so don't make sence to me, have more and better performance without intercooler.

Entaran · 03-17-06, 09:33 AM

The point of the intercooler isn't the extra power/torque. It's reduced charge air temperature which leads to reduced combustion temperature and longer engine life.

THAT is why you fit an intercooler.

Also, length of plumbing has been proven OVER AND OVER AND OVER again to have a total possible lag increase/decrease of 0.25 seconds across the metre or so of extra pipe. Those of you who are versed in physics can do the flow calculations yourself.

Intercooled Turbo's last longer than nonintercooled. They perform better and are less stressed. Everything is more durable. Mount the intercooler to the front, it doesn't have to be huge like the performance boys and the ricers but a standard intercooler off say an USSPEC Galant VR4 (OR JDM spec), or something of a similar size will be fine for you application. Pipework should be the same size as your throttle body.

Mickldo · 03-18-06, 07:09 PM

Slightly of topic. Have any of you seen the glycol/air intercoolers available over here for 1HZ/1HD-T motors. They look kinda like a hotdog muffler sitting on top of the rocker cover. They come with their own little remote radiator. Supposed to be more efficient than air/air intercoolers.

Tapage · 03-19-06, 07:45 AM

Quote:

Originally Posted by Entaran

The point of the intercooler isn't the extra power/torque. It's reduced charge air temperature which leads to reduced combustion temperature and longer engine life.

THAT is why you fit an intercooler.

In my case I plan go with an intercooler not for care my engine .. I go for it, to get more power .. for sure .. !

brownbear · 03-19-06, 10:17 PM

Quote:

Originally Posted by BJ40 3B

Some more:

looking at that photo you will not get any exhuast flow thru the turbo.....???whats changed, I see the flange welded on, but did you weld over the outlet? otherwise the exhaust just pours out...

MORE pics needed of your manifold......

BJ40 3B · 03-20-06, 11:23 AM

I haven't noticed that detail in the photo!!!
Now it's better!

R2HKS · 03-21-06, 04:51 PM

Intercoolers are definitely beneficial no matter what application they are applied to whether it be diesel or a gasser.

However of the 2 types I would consider water to air to be better for a diesel application based solely on the speed that 4wd's usually do. Air to air really only starts to work properly just like a radiator does over 70km/hr. In fact they are more efficient the faster you go and quite often you need to go over the speed limit to get the best benefit from them such as over 120km/hr.

Considering some of the fourbying I do like beach work where I rarely ever get over 70km/hr and can be using max throttle and really pushing the 3B hard a water to air would be a lot more efficient for this application.

Here is a pic of PWR water to air intercoolers as mentioned above they use a barrel style setup with separator radiator/pump resevoir etc.

Here's the details on the kits/prices:
http://www.pwr.com.au/pwr/index.asp

Air to air wise top mounts aren't worth it. They get heatsoak in no time. The only benefit is the short IC pipework aiding in good throttle response and less lag. VR4 IC's are good too as already suggested, though my personal preference for used IC's are Nissan GTR good for 300rwkw. Also truck IC's are good and you can get them cut down to suit and are very cheap as well.

andrea-PE-ITALY · 08-18-06, 08:01 AM

look at this if you like it. it is a volvo intercooler. At the end it will have a electric fan for pulling cold air from air bonnet, EGR and original air collectors connected with EGR will be removed. i'm making it by myself step by step with big calm..... i can't afford to make mistakes...

go to: http://album.foto.alice.it/andreape/965796

Tapage · 08-18-06, 08:51 AM

this is a huge intercooler dude .. !

andrea-PE-ITALY · 08-18-06, 10:06 AM

it is 60 x 40 cm it cames from volvo 2000 turbo gasoline (not diesel) i think it is right for 4164 c.c. of hdj80. i bought it on ebay from USA and i spent with taxes and spedition costs, less to buy it, USED, in italy at 5 km from my house

nickw · 08-18-06, 10:27 AM

Quote:

Originally Posted by andrea-PE-ITALY

it is 60 x 40 cm it cames from volvo 2000 turbo gasoline (not diesel) i think it is right for 4164 c.c. of hdj80. i bought it on ebay from USA and i spent with taxes and spedition costs, less to buy it, USED, in italy at 5 km from my house

Do you have any more pics of it?
Where does it draw the cold air from?

Cheers,
Nick

andrea-PE-ITALY · 08-18-06, 10:52 AM

Hi Nick, for cold air i will make an air cowling (scuse my english) on the bonnet. downstairs the intercooler, between engine, i will put an air fan about 16 inches for pulling air from cowling bonnet. i have over 3 inches between intercooler and engine. on the bonnet i will do 2 others air cowling for hot air removing. i have other photos but they are of the metal castle for keeping intercooler. if you want....i will send to you by email.
regards. Andrea

andrea-PE-ITALY · 08-18-06, 10:54 AM

i can tell you how to find it on ebay. you have to find "volvo intercooler" words. Just volvo and saab intercoolers, i think, are really fine for our car.

andrea-PE-ITALY · 08-18-06, 11:02 AM

look here:

http://cgi.ebay.com/ebaymotors/2002-...spagenameZWDVW

http://cgi.ebay.com/ebaymotors/Volvo...spagenameZWDVW

http://cgi.ebay.com/ebaymotors/Volvo...spagenameZWD1V

coldtaco · 08-18-06, 11:14 AM

Two problems I see with your set-up. One, you will need a really big hood scoop. Second, even with a fan beneath the intercooler, there is alot of area that will get heat soaked. If I was you I would look again at mounting to the front of the vehicle, or get a smaller size intercooler like from a Prado or Subaru type and mount it off to the drivers side where there would be less heat, maybe, than on the exhaust side and you will not need as big a scoop, plus you might be able to cut a hole between the hood structural supports. Or go with a water-air type. Keep us updated on how it does work if you still go this route.

andrea-PE-ITALY · 08-18-06, 11:42 AM

coldtaco i know what you mean. in my home made set-up air fan for pulling cold air will be activated by a thermal contact located on the intercooler. it will start not for hot air only but for hot location also. maybe i will be alwais switched on....like pajero, nissan etc.
the air cowling on bonnet will be 40x60 cm and the bonnet (i have 2) will be reinforced with vetro resin. Down by the intercooler, the mounting hardware of fan will be insulated from hot hair. Yes, this is an experiment but i think il will go well. I saw a Safari intercooler....too much long pipings and too lag due to long tubes. it works fine from 1600 to up RPM. but between 800-1600 there is too lag. i need short pipings. i will keep you updated abot my home made kit. x All of you: scuse me for my english, please, correct me

nickw · 08-18-06, 11:51 AM

With an intercooler, what would be a safe boost level on a 1HD-T.

Keep in mind I would still want to see the trucks 500,000 birthday.

andrea-PE-ITALY · 08-18-06, 12:31 PM

i think 0.90 atm max. don't know coversion in psi, scuse me.

nickw · 08-18-06, 01:13 PM

Quote:

Originally Posted by andrea-PE-ITALY

i think 0.90 atm max. don't know coversion in psi, scuse me.

Just did a converstion and thats only 13.22 psi.
That doesn't seem right. I run 12psi with no intercooler.

Cheers,
Nick

andrea-PE-ITALY · 08-18-06, 01:34 PM

try to take information about pressure with safari intercooler. in italy it costs too much. there are not many persons use it.

andrea-PE-ITALY · 09-12-06, 04:42 AM

my intercooler installation on top is going on.....

Tapage · 09-12-06, 08:34 AM

Nice .. veri nice .. !

fullnelson · 09-12-06, 10:24 AM

I can see the point that R2HKS makes about water to air IC's being more appropriate for 4x4's given the lower speeds they are generally used at. Does anybody have pictures or experience with a water to air IC on a Toyota diesel?

I am awaiting shipment of an AXT turbo for my 3B and looking at possible intercooling options. Thanks for all the good info. thus far.

andrea-PE-ITALY · 09-13-06, 08:40 AM

tapage, if you are interested at my job you can visit www.sahara.it there is the first part about my modify. Second part is in progress... but if yu want i have a document .doc with some other photos.
bye

Tapage · 09-13-06, 11:54 AM

Quote:

Originally Posted by andrea-PE-ITALY

tapage, if you are interested at my job you can visit www.sahara.it there is the first part about my modify. Second part is in progress... but if yu want i have a document .doc with some other photos.
bye

pm send .. !

bjowett · 09-15-06, 06:55 PM

You guys might consider the Toyota OE liquid intercoolers... this is one from a Celica ST165 chassis installed in my old 86 4-Runner 22RTE Turbo. It would probably be a good size for the B series, but a little small for the 6 cylinder engines.

Kief · 09-15-06, 07:52 PM

So how many of the toyota liquid to air coolers are floating around junk yards?

03-18-06, 07:09 PM	#34
Mickldo Oz TUTer Join Date: Feb 2006 Location: Maryborough, QLD, Aust. Posts: 1,021	Slightly of topic. Have any of you seen the glycol/air intercoolers available over here for 1HZ/1HD-T motors. They look kinda like a hotdog muffler sitting on top of the rocker cover. They come with their own little remote radiator. Supposed to be more efficient than air/air intercoolers. __________________ 90 HZJ80 GXL, DTS turbo, 285/75R16 MTR's, 4" OME, Safari snorkel, ARB airlocker, ARB bullbar, 9500lb winch, ARB dual pivot rear bar, 39L Engel, water tank, dual batts, sliding drawers, cargo barrier, underbonnet shower, laptop, GPS, oziexplorer, etc.... 99 HZJ105R GXL, alloy bullbar, Safari snorkel, more to come.....watch this space..........

03-20-06, 11:23 AM	#37
BJ40 3B IH8MUD Junior Join Date: Aug 2003 Posts: 87	I haven't noticed that detail in the photo!!! Now it's better! Last edited by BJ40 3B; 08-28-06 at 03:45 PM.

03-21-06, 04:51 PM	#38
R2HKS IH8MUD Rookie Join Date: Feb 2006 Location: Port Stephens, NSW, Australia Posts: 72	Intercoolers are definitely beneficial no matter what application they are applied to whether it be diesel or a gasser. However of the 2 types I would consider water to air to be better for a diesel application based solely on the speed that 4wd's usually do. Air to air really only starts to work properly just like a radiator does over 70km/hr. In fact they are more efficient the faster you go and quite often you need to go over the speed limit to get the best benefit from them such as over 120km/hr. Considering some of the fourbying I do like beach work where I rarely ever get over 70km/hr and can be using max throttle and really pushing the 3B hard a water to air would be a lot more efficient for this application. Here is a pic of PWR water to air intercoolers as mentioned above they use a barrel style setup with separator radiator/pump resevoir etc. Here's the details on the kits/prices: http://www.pwr.com.au/pwr/index.asp Air to air wise top mounts aren't worth it. They get heatsoak in no time. The only benefit is the short IC pipework aiding in good throttle response and less lag. VR4 IC's are good too as already suggested, though my personal preference for used IC's are Nissan GTR good for 300rwkw. Also truck IC's are good and you can get them cut down to suit and are very cheap as well. __________________ 81 BJ42 3B Ranchos, 31x10.5 Muddies Soon to be turbo!

08-18-06, 08:01 AM	#39
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	look at this if you like it. it is a volvo intercooler. At the end it will have a electric fan for pulling cold air from air bonnet, EGR and original air collectors connected with EGR will be removed. i'm making it by myself step by step with big calm..... i can't afford to make mistakes... go to: http://album.foto.alice.it/andreape/965796 Last edited by andrea-PE-ITALY; 08-18-06 at 08:22 AM.

08-18-06, 11:14 AM	#46
coldtaco IH8MUD Regular Join Date: Jul 2004 Posts: 481	andrea Two problems I see with your set-up. One, you will need a really big hood scoop. Second, even with a fan beneath the intercooler, there is alot of area that will get heat soaked. If I was you I would look again at mounting to the front of the vehicle, or get a smaller size intercooler like from a Prado or Subaru type and mount it off to the drivers side where there would be less heat, maybe, than on the exhaust side and you will not need as big a scoop, plus you might be able to cut a hole between the hood structural supports. Or go with a water-air type. Keep us updated on how it does work if you still go this route.

03-17-06, 09:33 AM	#33
Entaran IH8MUD Regular Join Date: Feb 2006 Location: Ballarat, Victoria, Australia Posts: 385	The point of the intercooler isn't the extra power/torque. It's reduced charge air temperature which leads to reduced combustion temperature and longer engine life. THAT is why you fit an intercooler. Also, length of plumbing has been proven OVER AND OVER AND OVER again to have a total possible lag increase/decrease of 0.25 seconds across the metre or so of extra pipe. Those of you who are versed in physics can do the flow calculations yourself. Intercooled Turbo's last longer than nonintercooled. They perform better and are less stressed. Everything is more durable. Mount the intercooler to the front, it doesn't have to be huge like the performance boys and the ricers but a standard intercooler off say an USSPEC Galant VR4 (OR JDM spec), or something of a similar size will be fine for you application. Pipework should be the same size as your throttle body.

08-18-06, 10:06 AM	#41
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	it is 60 x 40 cm it cames from volvo 2000 turbo gasoline (not diesel) i think it is right for 4164 c.c. of hdj80. i bought it on ebay from USA and i spent with taxes and spedition costs, less to buy it, USED, in italy at 5 km from my house

08-18-06, 10:52 AM	#43
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	Hi Nick, for cold air i will make an air cowling (scuse my english) on the bonnet. downstairs the intercooler, between engine, i will put an air fan about 16 inches for pulling air from cowling bonnet. i have over 3 inches between intercooler and engine. on the bonnet i will do 2 others air cowling for hot air removing. i have other photos but they are of the metal castle for keeping intercooler. if you want....i will send to you by email. regards. Andrea

08-18-06, 10:54 AM	#44
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	i can tell you how to find it on ebay. you have to find "volvo intercooler" words. Just volvo and saab intercoolers, i think, are really fine for our car.

08-18-06, 11:02 AM	#45
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	look here: http://cgi.ebay.com/ebaymotors/2002-...spagenameZWDVW http://cgi.ebay.com/ebaymotors/Volvo...spagenameZWDVW http://cgi.ebay.com/ebaymotors/Volvo...spagenameZWD1V

08-18-06, 11:42 AM	#47
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	coldtaco i know what you mean. in my home made set-up air fan for pulling cold air will be activated by a thermal contact located on the intercooler. it will start not for hot air only but for hot location also. maybe i will be alwais switched on....like pajero, nissan etc. the air cowling on bonnet will be 40x60 cm and the bonnet (i have 2) will be reinforced with vetro resin. Down by the intercooler, the mounting hardware of fan will be insulated from hot hair. Yes, this is an experiment but i think il will go well. I saw a Safari intercooler....too much long pipings and too lag due to long tubes. it works fine from 1600 to up RPM. but between 800-1600 there is too lag. i need short pipings. i will keep you updated abot my home made kit. x All of you: scuse me for my english, please, correct me

08-18-06, 11:51 AM	#48
nickw IH8MUD Lifer Join Date: Jul 2005 Location: Cranbrook BC Posts: 1,370	With an intercooler, what would be a safe boost level on a 1HD-T. Keep in mind I would still want to see the trucks 500,000 birthday. __________________ 1988 BJ74 / Lots of goodies - Sold 1990 HDJ81 / Fully outfitted loaded beautiful truck - Rolled 1985 BJ60 / Beautiful Stock truck - Stolen

08-18-06, 12:31 PM	#49
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	i think 0.90 atm max. don't know coversion in psi, scuse me.

08-18-06, 01:34 PM	#51
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	try to take information about pressure with safari intercooler. in italy it costs too much. there are not many persons use it.

09-12-06, 04:42 AM	#52
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	my intercooler installation on top is going on..... Attached Images

09-12-06, 10:24 AM	#54
fullnelson IH8MUD Regular Join Date: Feb 2006 Location: Western Colorado TLCA# 2664 Posts: 121	I can see the point that R2HKS makes about water to air IC's being more appropriate for 4x4's given the lower speeds they are generally used at. Does anybody have pictures or experience with a water to air IC on a Toyota diesel? I am awaiting shipment of an AXT turbo for my 3B and looking at possible intercooling options. Thanks for all the good info. thus far. __________________ Dirty Toy School TTT Backup Driver/ Trainer FJCTT Central Lead Driver 1972 FJ40 3B conversion, AXT Turbo, AA rock box, 116:1 crawl, Longfields 1993 FZJ80, Superwinch Husky 10, OME 851/863, ARB fridge, 285/75/R16 BFG Mud Terrains, Metal Tech sliders

09-13-06, 08:40 AM	#55
andrea-PE-ITALY IH8MUD Junior Join Date: Aug 2006 Posts: 82	tapage, if you are interested at my job you can visit www.sahara.it there is the first part about my modify. Second part is in progress... but if yu want i have a document .doc with some other photos. bye

09-15-06, 06:55 PM	#57
bjowett IH8MUD Lifer Join Date: Oct 2002 Posts: 1,767	You guys might consider the Toyota OE liquid intercoolers... this is one from a Celica ST165 chassis installed in my old 86 4-Runner 22RTE Turbo. It would probably be a good size for the B series, but a little small for the 6 cylinder engines. __________________ Brian Western Massachusetts 08 Tundra Double Cab 5.7 TRD 93 FZJ80, locked, 4.6L, 6 speed, Orion <- now driving! 04 VW Touareg V8 w/ locker (hers) 80 FJ40 , 83k, PS and AC 05 Yamaha RS Rage Snowmobile 06 Suzuki King Quad 93 VW Corrado Syncro AWD 3.0L 51 Jowett Jupiter Roadster

09-15-06, 07:52 PM	#58
Kief IH8MUD Lifer Join Date: Apr 2003 Location: Southwest Oregon Posts: 1,184	So how many of the toyota liquid to air coolers are floating around junk yards?