About to install intercooler on EU-spec HDJ80

[Jurgen van den Brink]

Hi all,
Finally came to the decision to have an intercooler installed on my HDJ80. The air-to-air kit will be delivered by All American Imports in Kaatsheuvel, The Netherlands. They have installed a lot of these over the last 15 years.
Last friday we examined the possibilities (due to the custom bumper and the winch mount) and they did not see too big problems. I hope to have the work done by the end of this month.
If you are interested in any specifics, just let me know.
Keep you posted, Jurgen

 

[lumpy70]

I'm definitely interested in this build.

Please post pics and details as they come!

Craig.

 

[IanB]

Also interested!

 

[Tapage]

keep the pics comming ( or start )

 

[Jurgen van den Brink]

Not all parts are in stock at this moment, so now the installation is planned for second half of November... Keep you posted!

 

[djsherif]

What's the cost of the system?

 

[Enigma]

Subscribed! I'll be adding this to the Official Intercooler thread when you are done


All American Imports BV - 80 series performance parts

So about All-American, any idea if they have a North American vendor?

 

[Vegard]

You will be happy with the kit from AAI. It includes absolutely every little piece needed for installation, even brake fluid. (a bracket holding the brake lines must be replaced, meaning some fluid will drip out)

I have run this IC in my 24-valve 80-series for 6 months now. My aftermarket turbo (Gturbo) is set to boost 1.45 bar at maximum. At this boost level the pressure loss is only 0.06 bars.

After driving for 30 minutes in 130 kph, boosting between 1.0 and 1.2 bars all the time, the IC is so hot on the turbo side that I would not keep my hand on it. On the other side it was totally cold. Outside temperature was around 20 C.

EGTs are reduced significantly. As an experiment I recently bypassed the IC, again using the original piping. EGTs would then jump way too high if I tried to accelerate like I use to. (my pump is tuned for high boost and IC)

The IC from All-American Imports really works well.

 

[Tapage]

that's sure huge IC .. how much space you have between it and AC condenser..?

 

[Vegard]

that's sure huge IC .. how much space you have between it and AC condenser..?

Not much, but enough:

I think 80s with an automatic transmission have to relocate or replace their transmission cooler.

 

[Tapage]

Not much, but enough:

I think 80s with an automatic transmission have to relocate or replace their transmission cooler.

you betcha .. and it fits with the factory grill .?

thanks for that pic .. !

 

[Vegard]

you betcha .. and it fits with the factory grill .?

thanks for that pic .. !

Yes the factory grill fits. The mounting points in the center of the grill are used no more, and have to be trimmed. Some trimming must also be done at the bottom of the hood locking mechanism. The kit supplies a replacement hood lock support that gives room for the IC.

The only concern is that large tires could rub the hoses where they go outside the of the frame. My 33" tires have enough clearance, with stock rims. With 1" spacers there is more room.

The IC drier has to be moved a little. I have since the pictures where taken replaced my drier and piping due to leakage. The drier now sits in the enginge compartment out of harms way.

 

[Jurgen van den Brink]

Last look at the empty bay: I'm going to pick-up the Cruiser today!
Keep you posted, Jurgen

(hope I do the uploading right...)

 

[Jurgen van den Brink]

And the final product!

All set to go!

The intercooler fits nicely, it has been more work than expected, but the guys from All American Imports worked everything out fine.
I did not have much chance to test the extra power, although the Cruiser really feels easier on the throttle. They also installed the EGT sensor in the manifold and it is now hooked on the MadMan Engine Monitoring System. The only thing I have to with that respect is to install the engine oil temperature sensor in de oil pan plug, although the adapter is not easy to find over here in The Netherlands.

Cheers, Jurgen

Pictures are not displaying too much, I guess... There is not enough space left.

 

[Jurgen van den Brink]

and pics of the tubing and EGT

Up for the next project!

 

[IanB]

Looks good!

 

[BJ42 Daniel]

My old lovely car!!! In good hands I can see!