Intercooler on a TD42T

Post by **Screwy** » Wed Mar 18, 2009 9:00 am

I bought a Turbo diesel shorty GQ a few weeks ago....
Its aftermarket Turbo.

Been talking to a few ppl, am interested in intercooling it.

Im interested in what the main advantages and disadvantages of doing this are and if its worth the cost?
And what the cost would be to do this.... I can do it myself if im pointed in the right direction.

Whats involved in doing it and what parts and tech can you guys give me on this conversion. Cant find anything on this in the bible. only mentions turbos, not intercoolers.

lastly has anyone got any pictures on how they have done this and where they have mounted the intercooler? cause i cant see a great deal of room.

cheers guys

Screwy

Post by **kond** » Wed Mar 18, 2009 9:34 am

I used a pwr Air to Water Barrel type intercooler Should have it dynoed in a month or so . I will let you no how it goes. About $1850.00 to finshed product

Post by **bogged** » Wed Mar 18, 2009 9:52 am

Turbo - do you have a high mount turbo, or low mount (on manifold). Low mounted manifold ones are easier to intercool if you want top mount.

Do you want air/air or water/air.. Eg do you have room for another radiator? Checked out the laminova thread?

How much do you wanna spend.

What HP exactly are you aiming for?? work that out then you can work out what size intercooler to go for.

Work out do you want top or front mount.

Both have + and - to them.
Front mount more suseptable to damage
Top mount suffer from heat soak from engine.
etc
www.are.com.au has some great info on i/coolers in general.

If you want cheap and easy, you can get the std GU 4.2 ones for few hunge with all mounts complete. They arent the biggest or best, infact are the same one as on the 2.8 GU, but are cheap and bolt up easily.

Then you can extend them like Awill4x4 did with my old spare one.

HTH a little.

Post by **sidewayz** » Wed Mar 18, 2009 11:35 am

im in a similar position, i would like to intercool my turbs td4.2.

i was looking at air-air frount mount but dont wana have another thing in front of my radiator as most turbo gq owners would know keep them cool is hard enough.

top mount seems less effective and gettin air to it is a bit of mucking around.

water to air is quite expensive andrequires a lot of plumbing and once again more blocking the radiator.

with all this in mind is why my gq has remained non intercooled atmo. (also cause i havnt been feeling motivated lately, haha)

Post by **bogged** » Wed Mar 18, 2009 12:12 pm

sidewayz wrote:water to air is quite expensive andrequires a lot of plumbing and once again more blocking the radiator.

not expensive if you go the GT Liberty one discussed recently.

The intercooling GQ/GU hasnt been asked before suprisingly

(just threads on subaru ones)
http://www.outerlimits4x4.com/phpBB2/ftopic165904.php
http://www.outerlimits4x4.com/phpBB2/ftopic35856.php
http://www.outerlimits4x4.com/phpBB2/ftopic35856.php
http://www.outerlimits4x4.com/phpBB2/ftopic117172.php
http://www.outerlimits4x4.com/phpBB2/ftopic141950.php

Post by **Screwy** » Wed Mar 18, 2009 2:57 pm

The main reason i want to look at this is for towing, i want it to have abit more grunt when towing and possibly keep it cooler in general towing long distance.....

Not really after a specific horse power figure as such, more just general all around improvement mainly when towing and also when pushing the 35's around......

I have the airconditioning working and fans associated in front so there is really no room up front for an intercooler.

Id be looking at a top mount intercooler by the sounds of things air to air might be easier???

My current setup is a Dynamic Turbo... It bolts up under the exaust manifold and runs into the air box and also runs over the top of the engine into the top of the inlet manifold.

what sort of improvement and costs would be involved in a setup like this?
whats involved in modifying to intercooler from my existing setup?

screwy

Post by **sidewayz** » Wed Mar 18, 2009 5:35 pm

do u mean the airbox is in the corner of the engine bay? or on top of the motor?

if its on top of the motor then the easiest option is track down a grenade airbox and it wil bolt striaght in. then u have plenty of room on top of your motor for either air to air or water to air.

Post by **GU-ish** » Wed Mar 18, 2009 6:09 pm

im looking into putting one on my GU 4.2
would like to go the air to water but the wallet wont let me so probs looking at putting a top mount cooler... if ya have a look on ebay you can pick up small inter coolers pretty easy and its more of a chance that the silicone bends are gunna cost more than the cooler its self!, dnt forget to add this into your price as i have boon looking aorund and average price is about $60-$80 for each bend....

anyone who has put a top mount in throw up some pics

Wed Mar 18, 2009 6:40 pm

this is before it is finnished

i have sinse built a shrowd under it with a fan but i need a bit more room so im going to lift the body 15mm or so , and fit a spal fan under the intercooler , the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power

Post by **bogged** » Wed Mar 18, 2009 6:46 pm

GU-ish wrote:would like to go the air to water but the wallet wont let me

that subaru setup goes for $295 on ebay complete ready to go.. subaru forums they go for $100 complete ready to go, but are rocking horse shit rare these days.

Post by **GU-ish** » Wed Mar 18, 2009 7:05 pm

would a thermo fan under a top mount help with keeping the heat down.. ie. fan sucks air through and pushes down towards motor.... mayb on slower tracks in the bush?

Post by **Screwy** » Wed Mar 18, 2009 7:12 pm

sidewayz wrote:do u mean the airbox is in the corner of the engine bay? or on top of the motor?

if its on top of the motor then the easiest option is track down a grenade airbox and it wil bolt striaght in. then u have plenty of room on top of your motor for either air to air or water to air.

Well at the moment,

The snorkel runs into the rectangle airbox thats at the back of the motor ontop of it, the turbo also runs into the bottom of the airbox as well at one point. It then runs across the top of the motor infront of the airbox to the top of the inlet manifold....

seems like abit of dickin around involved. Ill take a couple of pics of my engine bay tomorrow and post up, see what you guys think.

screwy

Wed Mar 18, 2009 7:15 pm

GU-ish wrote:would a thermo fan under a top mount help with keeping the heat down.. ie. fan sucks air through and pushes down towards motor.... mayb on slower tracks in the bush?

yep but as i said above
the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power , so basicly you want to stop any hot air from the radiator or engine from going through the intercooler and a well seaked shrowd and fan will make a huge difference

Post by **GU-ish** » Wed Mar 18, 2009 7:37 pm

the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power [/quote]

so wat could be used? like a sheet of something attached to the underside of the cooler with enough room to let air flow from the top out the bottom?

Post by **bogged** » Wed Mar 18, 2009 7:51 pm

GU-ish wrote:the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power

so wat could be used? like a sheet of something attached to the underside of the cooler with enough room to let air flow from the top out the bottom?[/quote]The GU bonnet scoop comes with the rubber seal that seals to the intercooler.
Some Grenade owners run IC fans under the cooler to keep them cool but I wonder how good they really are.. at hwy speeds, would they hinder the flow....

Wed Mar 18, 2009 8:03 pm

bogged wrote:
GU-ish wrote:the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power
so wat could be used? like a sheet of something attached to the underside of the cooler with enough room to let air flow from the top out the bottom?

The GU bonnet scoop comes with the rubber seal that seals to the intercooler.
Some Grenade owners run IC fans under the cooler to keep them cool but I wonder how good they really are.. at hwy speeds, would they hinder the flow....[/quote]

alot of people recon even at hwy speeds you get bugger all air flow through them thats why i figured you may aswell just use a thermo fan with a shrowd like a radiator to suck the air through the entire intercooler , not just where the fan sits

ive just used a bit of tin shaped into a shrowd with the fan secured to it

Post by **GU-ish** » Wed Mar 18, 2009 8:19 pm

do you have a pic of what you made?

Wed Mar 18, 2009 9:03 pm

GU-ish wrote:do you have a pic of what you made?

nope , but i will be changing mine soon and fitting a bigger fan under it for more airflow so i will get pics then

Post by **Screwy** » Sat Mar 21, 2009 6:18 pm

OK, pics of my current turbo setup.

What are your thoughts on my best option???

Screwy

Post by **ozy1** » Sat Mar 21, 2009 6:41 pm

okay, to make some room to run a top mount, or a water to air intercooler, you can pick up a GU patrol RD28t, ZD30 or TD42 air box, it will bolt in behind the drivers head light with a few small mods,

the pick of the 2 airboxes is the ZD30 or the RD28 as they have a larger internal id on the air box lid,

i fitted a ZD30 box, all i had to do was remove the MAF flange and some 3" hose slipped straight over, i joined the snorkel and airbox with some 3" hose through the inner guard,
i did have to move the ARB battery tray 30-40mm towards the firewall, but other than that it was pretty straight forward,

i also think there will still be enough room to run a front mount intercooler as well,

Sat Mar 21, 2009 9:05 pm

its aford not a nissan wrote:this is before it is finnished

i have sinse built a shrowd under it with a fan but i need a bit more room so im going to lift the body 15mm or so , and fit a spal fan under the intercooler , the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power

how do you top up the oil the cap is coverd

Post by **Screwy** » Sun Mar 22, 2009 9:52 am

ozy1 wrote:okay, to make some room to run a top mount, or a water to air intercooler, you can pick up a GU patrol RD28t, ZD30 or TD42 air box, it will bolt in behind the drivers head light with a few small mods,

the pick of the 2 airboxes is the ZD30 or the RD28 as they have a larger internal id on the air box lid,

i fitted a ZD30 box, all i had to do was remove the MAF flange and some 3" hose slipped straight over, i joined the snorkel and airbox with some 3" hose through the inner guard,
i did have to move the ARB battery tray 30-40mm towards the firewall, but other than that it was pretty straight forward,

i also think there will still be enough room to run a front mount intercooler as well,

So is yours a top mount shawn?

Wouldnt be sure where in the front. only way i can see is if i butcher the shit out of the front grill....
with the radiator and aircon condensor and 2 thermo fans on the front of that it really looks like ill have no room up front......

Post by **ozy1** » Sun Mar 22, 2009 11:15 am

nuh i havnt intercooled mine yet, but if you remove the large air box from the top of the motor and run the GU one behind the grill it will give you more room,

but if i were you id look at going with a water to air intercooler, this is what ill bee fitting when i get time and cash,

Post by **Screwy** » Sun Mar 22, 2009 5:31 pm

ozy1 wrote:nuh i havnt intercooled mine yet, but if you remove the large air box from the top of the motor and run the GU one behind the grill it will give you more room,

but if i were you id look at going with a water to air intercooler, this is what ill bee fitting when i get time and cash,

Well ive got the duel battery setup in there with a snorkel on the passenger side.... not sure if ill be able to pipe the air to a box on the drivers side behind the headlight, also unless the airbox your talking about is very small it wont fit in there either.....

Also i know i havent got room for an air one infront of the radiator unless its so small its pointless....

Looking at it now though, it would probably be quite easy to run a water one like in the pics above, it seems to be that all i have to do is wack it in between the inlet manifold and turbo??? can leave it above the motor and leave the current airbox setup all where it is as well...?

the thing im wondering.... where does the water pipe from and how do you run all the water setup in these? its not engine water is it???

Screwy

Post by **ozy1** » Sun Mar 22, 2009 7:19 pm

the GU air box is a decent size, if you have the ARB battery tray, you have to move the battery towards the fire wall by about 30mm then it will bolt straight in, i had the setup ion my old wagon, but have since stripped out the duel battery system out so pics would be pointless, i will be installing this setup into my sisters SWB in about a month so will be able to get pics then,

its a pretty straight forward job and gives you even more room above the motor,

http://www.outerlimits4x4.com/ftopic111 ... ght=airbox

Post by **bogged** » Sun Mar 22, 2009 7:24 pm

hillbilliywheelchair wrote:
its aford not a nissan wrote:this is before it is finnished

i have sinse built a shrowd under it with a fan but i need a bit more room so im going to lift the body 15mm or so , and fit a spal fan under the intercooler , the trick with top mounts is they need a shrowd and have to be sealed from the engine heat or heat soak will rob you of power
how do you top up the oil the cap is coverd

thats why the one at the top Andrew made, stops before oil cap. Also gettin enough air flow..

Post by **Screwy** » Mon Mar 23, 2009 4:24 pm

Ah ok so you run the GU air box on the passenger side behind the headlight and so the snorkel connects up to it???

Looking at it though....

If i run a water style intercooler..... I might not need to move the airbox at all which could make things abit cheaper....

My main question if anyone knows how do you pipe the water side of things to it? Does it come from the engine water or does it come from another source and if this is the case, what is it and how does it come together?

screwy

Post by **ozy1** » Mon Mar 23, 2009 4:42 pm

water to air intercoolers have their own radiator and thermo fan which goes in front of the engine radiator.

http://www.frozenboost.com/

Post by **matt.mcinnes** » Fri Mar 27, 2009 3:52 am

26% more KW 29% more torque.

From this

To this

DYNO'D before and after

Full info search LAMINOVA

Post by **sidewayz** » Fri Mar 27, 2009 10:05 am

how are your engine temps now you have the extra radiator in front of your air con and engine radiator? before and after under load?

also, is your engine radiator standard or upgraded?

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