1KZ-TE Custom Top Mount intercooler mount fan shroud + 200mm Fan (underneath intercooler)

Joined
Apr 3, 2022
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40
Location
Adelaide, South Australia
In an attempt to reduce EGTs and engine temps whilst towing, sand driving, sitting in trafic on hot days etc, I thought I'd have a crack at raising my top mount intercooler roughly ~70mm and mounting a 200mm fan underneath to draw air down through the intercooler. After some further brain storming with a friend, I decided a shroud would greatly improve this design so I whipped up a shroud in my lunch break at work. Had to do all the bending with a hammer and clamping the 1mm sheet between two pieces of 10mm steel plate so excuse the wobbly finish haha. This will be hidden anyways so you wont see it. Pretty happy how it turned out! Its a very snug fit and utilises the existing mounting brackets holes to secure it however I'll likely run some high temp silicon or something around it to make sure it is properly air tight and prevent vibration noises once I know it will all fit. Haven't tested yet as I am waiting for a new refurbed engine to arrive any day now and will hopefully have it in by EOW.

I am not 100% sure this will fit under my bonnet however I'm just going to roll with it, see how it goes and make further modifications to accomodate it if need be. I'm pretty sure there was a bit of head room with the old engine in so am quietly confident i'll have no dramas. Anyways, just thought i'd share this project here for anyone else who has had thoughts of doing something similar. I'll post updates when I have some results!

Cheers, Sam

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Joined
Apr 3, 2022
Messages
40
Location
Adelaide, South Australia
Found this the other day. These guys reckon they've had some success with this bottom mounted shrouded fan design so I'm becoming confident this is going to work. See here for their Youtube video demonstrating their findings:
Fingers crossed I have the headroom under the bonnet to raise the intercooler the ~70mm required to fit. New engine arrives today so once thats in, i'll know for sure! I think next step to improve this system is a larger/wider bonnet scoop to draw in more air. The scoop I currently have is only small and joins in with the factory air intake. And finally I have ordered all the parts to build a custom 2 3/4" stainless steel snorkel (for under $200) and no welding! I'll do a separate post on that soon once I get some pics of it coming together.
 
Joined
Apr 3, 2022
Messages
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Location
Adelaide, South Australia
Well I finally had a chance to fit in the new fan and shroud setup. Unfortunately the final result would mean the black plastic top of the intercooler would end up about 10-20mm above the top of the bonnet :( This is due to that annoying bloody "hump" in the middle of the rocker cover (valve cover) which forces the height of the setup upwards by roughly 70mm. Is that hump even necessary or just a design thing? Can I find a flat rocker cover to replace it and solve my height problem? Any suggestions would be greatly appreciated!

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Joined
Apr 3, 2022
Messages
40
Location
Adelaide, South Australia
Just a quick update so as to not leave this thread incomplete, due to the head f#ckery above and advice from others in other forums, I think i'm gonna ditch this idea and am now taking an interest in a "water to air" system instead. Shame as this was a fun project but too much of a headache to make it work without a body lift or modifying the rocker cover which i'm not feeling that inspired to do. Back to the drawing board! :)
 

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