Intercooler

[Jack_Lives_Here]

Looking at having an intercooler added to the rodeo - 2002 model (old style) 2.8TD. Have seen the Safari front mounted jobs - not a fan - looks like they bloke alot of air flow to the radiator. Is there anyone in Brissy that does a top mounted unit??

[Big_Kev]

The one at the front is usualy called an after cooler.
Any good turbo shop will be able to do the job, but for the horsepower increase I would think it not be worth the money.
Better exhaust flow is much better or fuel pump can be tweaked to increase the fuel supply and exhaust temp.
Also may help to make slight adjustment to the fuel injection timing and adjustment to make the engine RPM slightly more.
This is a specialist job and not for the backyarder.(can end up with a bang)
Cheers Kev. #:)

[TimNQ]

topmounts are not worth it. heat soak will occur and you may aswell heat your air over a fire before sucking it through your enging. Get a nice big front mount, i dont see it doing too much to your radiator. I had a 100 mm garrett core stuffed in front of my radiator and made no difference to the running temperature of the car.
Kev, fitting an intercooloer will not increase horse power no. BUT it will enable him to be able to safely wind the boost up for more power, which in turn will do alot more than a fuel pump tweaking. If your looking for power with this thing, my choice would be to get an intercooler, programmabl;e ecu, secondary stock fuel pump to run parralel with the stock one. this will up the pressure by a fair way. 3" exhaust from turbo back and just get rid of the internals of the catalytic converter. K&N replacement filter(NOT POD)
Now this setup should allow you to safely wind up boost to maybe 15psi :D without boosting hot air. The secondary fuel pump creates that little bit more pressure which will take your duty cycle down a fair way which means your extra boost isnt being starved for fuel. And with the ecu, you can play around with all different types of settings and make sure you get someone you trust to tune it. i gained 40 kw just from a retune once. The idea with exhaust gasses, unlike non turbo cars, is to get rid of it as quick as possible. so 3 ": is the only way with this size engine and make sure the turbo dump is also 3 ". Then after thats all done, can look at turbo upgrades, hyflowing is reasonable and creates twice the airflow of the stock unit and the internals are built strong enough to handle alot more boost. Then start thinking about other ways you can get the air to enter the engine colder ie. cold air induction. There is tones of ways to get more power in turbo vehicles and adding an intercooler IS one of them. Give me a pm with your number if you want to know anymore and ill help out where i can.
Tim

[TimNQ]

another way to help that air flow to radiator prob if it is getting bad. water alcohol spray setup to finely mist the radiator core. this way you dont have to compromise the placement of the cooler core. front is the best place for it.

[Big_Kev]

Tim an intercooler or aftercooler will increase the horse power, but not enough to make it worth spending the sort of money invloved.
Like we have said, it is better to improve the waste flow to improve torque rise from this Turbo Diesel engine.
Cheers Kev.

[TimNQ]

ok ill settle down, im talking from petrol turbo experience mainly, however an intercooler wont make much more power alone, no, but it also makes it safe to wind up boost which i n my opinion, deisle or petrol, means more power and well worth the money spent on intercooling.
Tim

[Big_Kev]

Thats correct Tim.
Fuel make combustion temp that creates expansion that creates more boost as it exits.
The cooler cools the charged air and stops the China Syndrome happening with the pistons, but that is getting serious.
For the Diesel Rodeo I don't think he wants a racer so he is best to stick with the simple stuff.
Cheers Kev.

[TimNQ]

yea i wouldnt think hed want a power plant either but he was looking at intercooling so i thought he may have wanted to get some power out of the little engine. i agree totally though, if your just looking for little bit more torque then there are other ways of getting it much cheaper.
Tim

[Jack_Lives_Here]

Yes - would like a few more Kw's from the motor. Looking at figures quoted seems to be a reasonable increase. 2 guys I spoke to also agreed with the power increase.

[Big_Kev]

Is the blue line a turbo engine or normal aspiration(std).
22kw power increase from an intercooler, which is about 25% from just the cooler??
Can you get a graph on the torque figures Nm for a comparison as well?
I still would recomend you go to a 2.5 inch exhaust before you go for the cooler. You will be suprised with the difference that this would make.(cheaper to) ;)
Cheers Kev.

[Jack_Lives_Here]

Blue line is the std 2.8turbo engine. I would plan to have new pipes and have the injectors tuned also.

[PinHead]

An intercooler does increase horsepower. A turbocharger heats the air as it is compressed. By cooling the air you make the air more dense therefore there are more air molecules in the same volume which is more air to burn the extra fuel therefore more power.

[DaneCross]

Gday Dave,
How do you find the Rodeo in general? Looking at upgrading from an '84 hilux to a 2000+ model Rodeo. Is it lacking power, or are you just getting greedy? How does it handle off-road/heavy loads? Anyone offer an opinion on turbo diesel vs V6 petrol models?
Cheers,
Dane

[Jack_Lives_Here]

Love the Rodeo - just getting greedy. Towed my 4.5m Hornet and three big guys to hinchinbrook last Sept all on about 12l / 100km. Haven't had it in any serious off road stuff yet - mainly use it for towing etc.

[TimNQ]

Pinhead that has been discussed and hes not looking for that much power, i thought it would be a goer with other mods.. there are cheaper things to do to gain power without even touching the boost though. But once everything is refined then a cooler and more air would be the objective.
Like REEL HARD said, better exhaust flow will make a huge diffewrence, there is a chance that your exhaust is already restricting any further power increase, you may also find the boost rise up a psi or so just by exhaust increase. Get a replacement k&n panel filter( #Dont go pod, unless your going to box it up with cold air induction.). Thes filters are expensive but they last a lifetime and are washable with much better flowing capabilities. Fuel pump leaves a few options, you could get a after market high pressure pump or like ive said before, just hook up a second stock pump and plumb it up parrallel.
You can have your injectors cleand and high flowed to sqirt more fuel which costs about 500 bucks, but thats another thing that wont be necissary till your winding up the boost and looking to cool it. An after market ecu which is programable will come in handy if you ever want more boost and fuel. Just dont get an intercooler and think it will do anything without winding up boost which will then lead to upgrading everything ive just mentioned to do it safely and properly.There is heaps more that you can do to gain power without spending big bucks. just do your research before you do anything.

[Jack_Lives_Here]

TimNQ - This is not a high performance race car i'm talking about here - it's a stock as a rock diesel. The "research" you mention is exactly what i'm doing and the research suggests that pinhead was right on the money. You shouldn't concern yourself with how much money I have to spend. I reckon $1900 on a cooler and then tuned by the same people is money well spent. Hey, guys I've spoken to since first posting this are all 1000% happy with their choice - same vehicle same cooler. ;) ;)

[Big_Kev]

Well it sounds like the cooler is the choice for the day Jack.
Still the first step is to do is the exhaust. It sounds like the guysyou have lined up to do it have done the job before plenty of times.
I just find it hard to beleive that just a cooler will give that sort of an increase as displayed in the graph without carrying out other mods
Be sure to post some pics and tell us what she goes like after the job.
Cheers Kev. :) :)

[TimNQ]

TimNQ - This is not a high performance race car i'm talking about here - ##


Thats why a cooler is a waste of time and money when there are so many other restrictions costing you power without having to do what people tell you and spend big bucks. 7-8psi does not need to be cooled. But yea your choice and good luck with it.

[Jack_Lives_Here]

Yeh Kev the guys that were happiest had new exhaust put on also - that's in the plan also.

Tim - let's just say I want to retain fuel economy as well.

[Big_Kev]

If you are doing the exhaust 2.5 inch will do the trick.
The 3 inch is realy for the above 5 ltr class and is mainly fitted by guys who read to many magazines.
3 inch has to be manualy fabricated and can cost an arm and you don't realy need it.
But if you want put 3 inch from the turbo to the resinator this is where the exhausted gas will be at its hottest after that it cools very quickly.
Cheers Kev :) :)