J4 Diesel Intercooler retrofit, ... (2 Viewers)

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Joined
Feb 23, 2022
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Location
Brazil
Bom dia,

I have a '89 Toyota Bandeirante with the Mercedes Engine and got 'em a turbo upgrade like 4 years ago. Since then I'm driving this setup without issues.
When I was installing the turbo, it took me quite some tim, because it wasn't a Plug'n'Play kit or so and I had to upgrade some other stuff as well. I spared out the intercooler back then.
It's a unregulated turbo which delivers around 15PSI of boost at redline limit (and less at lower RPMs). The engine was never build for turbos, so I do not have a boost controller, I just cranked up the diesel a bit and drive like this. I watch the EGT closely (EGT Meter before turbo) and try to keep the black smoke little by avoiding a heavy foot at low RPMs.

Once in a while I' thinking about the intercooler and I could need some piece of advice from you guys:
1. I know, that there is no additional power just because of the IC, but it will thematically relief the engine a bit
2. How big will the drop of EGT be? Like roughly?
3. If I crank up the fuel further to meet the same EGT as before, will that be a big difference?
4. Any fuel savings?

The successor of my engine was build with a OEM turbo and was delivered in different versions and the turbo alone had something like 110hp and the turbo+intercooler went up to almost 140hp. I somehow doubt, that I can get up there. I have right now around 85hp on the rear wheels with around 20hp-25hp loss in the drive train and wheels (acc to the dyno).

I would go for a more or less similar IC-size as the 140hp engine and squize it infront of the climacooler. The electric fans would need to go, not enough spare and I would need to bring the radiator a bit back anyhow.

What you guys think, worth the effort? Cost wise I would end up at around 450USD roughly, building the kit myself and get some stuff welded by a local shop.

WhatsApp Image 2025-08-12 at 08.08.13 (1).webp


WhatsApp Image 2025-08-12 at 08.08.13.webp
 
1 You likely will pickup some power especialty since you do not have an ALDA (Mercedes talk for boost compensator) and are currently getting some smoke without one.
2-4 : probably, too many unknown variables

you'll have to keep your rad temps in check and your AC may not work as well without those electric fans and even more heat to deal with. a radiator shroud would help with both. fixed or clutched fan? what core size do you think you can fit in there?
 
I was looking for a LDA, but it would mean, I need to change the whole pump for the successor model and those are a bit rare = expensive.

The AC works without those elec fans as well, but for sure better with. The idea was to get rid of the fixed fan for the engine, but that doesn't really work.

The core size will be around 570x30x40 mm, there is a bit bigger version with 50mm
 

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