Added an intercooler

Post by **Vulcanised** » Sat Jan 22, 2005 11:46 am

I just added an intercooler to my 2.8 T/D rodeo (4jb1t engine) it made a little difference to the power without being retuned....... a bit more torque..... and the turbo sounds like a Mack truck as i accelerate and change gears...... sounds good actually

I know it will go a heap better once it is dyno tuned...... does anybody have an idea on roughly what increase i can expect when it's re-tuned? I have been told about 25kw extra... and up to about 70nm increase in torque. Any ideas?

Post by **-Richo-** » Sat Jan 22, 2005 6:27 pm

RoeDao wrote:I just added an intercooler to my 2.8 T/D rodeo (4jb1t engine) it made a little difference to the power without being retuned....... a bit more torque..... and the turbo sounds like a Mack truck as i accelerate and change gears...... sounds good actually I know it will go a heap better once it is dyno tuned...... does anybody have an idea on roughly what increase i can expect when it's re-tuned? I have been told about 25kw extra... and up to about 70nm increase in torque. Any ideas?

Not sure on the KW gain, but did you go top mount or front mount? I am considering installing an intercooler as well but im undecided on where to mount. Front i asume will give better gains, but a PITA to plumb, could hamper radiator cooling. Top mount will not give as much gain but is a much easier install.

Anyway would be interested to see how you go after the tune up.

Post by **Vulcanised** » Sun Jan 23, 2005 5:23 am

i did a front mount....... i got an intercooler off a 13B rotary and adapted it. I was originally going to do top mount, but i got airbrushing done on the bonnet and didn't want to cut it up putting a scoop on it. The engine seems to run a little cooler with it. The thermos don't seem to be cutting in as frequently.

As for the plumbing, it was a pain initially, until i moved the battery to the back. That made life a lot easier........... now i have to get a battery box for the thing.

Post by **-Richo-** » Sun Jan 23, 2005 8:07 am

Looks nice and neat, and doesnt block your radiator too much, i could get my hands on a cooler of about the same size pretty cheep so let us know how you go after the tune up!

Dont know if you noticed or not but your holden badge is upside down

Post by **Vulcanised** » Sun Jan 23, 2005 5:10 pm

Drop Bear wrote:Dont know if you noticed or not but your holden badge is upside down

couple of zook guys did it...... so that when the recover the vehicle, they know what it is before they turn it over

I thought it was a good idea.. so i kept the trend going

Post by **-Richo-** » Mon Jan 24, 2005 6:21 pm

RoeDao wrote:
Drop Bear wrote:Dont know if you noticed or not but your holden badge is upside down

couple of zook guys did it...... so that when the recover the vehicle, they know what it is before they turn it over I thought it was a good idea.. so i kept the trend going

that just might come in handy one day.

Do you have a boost gauge? if so did you notice any pressure drop after installing the cooler? Youve now got probably 4 times as more space to pressurise now, just wondering if that has made any difference to the boost. But you say youve got more power so i am assuming its not really an issue.

Post by **Vulcanised** » Tue Jan 25, 2005 4:32 am

i lost about 1 pound of boost.... but it still goes better

i'm guessing there will be a couple more pounds when it's tuned.

Post by **MudLux101** » Tue Jan 25, 2005 11:05 am

looking good mate.

just wondering what you have airbrushed on ya bonnet. do you have a clearer pic of it?

Post by **Meldge** » Tue Jan 25, 2005 4:01 pm

Does boost now come on a little later...?

Post by **Vulcanised** » Tue Jan 25, 2005 4:12 pm

MudLux101 wrote:looking good mate.

just wondering what you have airbrushed on ya bonnet. do you have a clearer pic of it?

There ya go

this was just before i bolted it back on.

Post by **Vulcanised** » Tue Jan 25, 2005 4:14 pm

Meldge wrote:Does boost now come on a little later...?

no... it actually feels like it comes in earlier...... could be because i removed a restriction on the inlet manifold when i made the adaptor for the 2" hose... the previous adaptor had a diametre of about 1 1/2"

Post by **Roctoy** » Tue Jan 25, 2005 4:35 pm

now that it's intercooled, wind up the boost a little. keep it under 15psi though.

THEN YOU WILL NOTICE A DIFFERENCE!

Post by **ca18escort** » Tue Jan 25, 2005 10:14 pm

The pressure drop that you are experienceing come from that fact that the air has been cooler thus making it denser. ie you have the same mass of air but it is taking up less volume.....Boles law. You will still have the same power. This is why intercoolers are kewl. but yes you should up the boost pressure and make sure that you put a good egr temp sensor on the exhaust so that you can get the mixtures right. Diesels run better on a lean mixture as a rich one will send the EGR Temp through the roof.

Cheers
Paul

Post by **Vulcanised** » Wed Jan 26, 2005 4:26 am

i'm taking it to Scotts Dyno Tune in Newcastle...... 100 bux per hour to do it :roll:

they said it would take a minimum of 1 hour, maybe 2 to get it done. Personally, i can't see it taking more than one hour, there is no timing belt to mess with.

Post by **mickbeny** » Wed Jan 26, 2005 6:16 pm

Hi all...RoeDao,for about $30 you could go to MTQ[turbo specialists] at Warrabrook[2 doors up from Opposite lock] in Newcastle,They will hook up a boost guage and EGT guage and take it for a spin and set accordingly.It will probabaly take them half hour.

Post by **Vulcanised** » Wed Jan 26, 2005 6:22 pm

mickbeny wrote:Hi all...RoeDao,for about $30 you could go to MTQ[turbo specialists] at Warrabrook[2 doors up from Opposite lock] in Newcastle,They will hook up a boost guage and EGT guage and take it for a spin and set accordingly.It will probabaly take them half hour.

WOW!! thanks!! hehe i can get it done sooner at that price!! :armsup:

Thanks a heap!! bit hard to tell in figures what the increase is....... but what the hell!!! at that price ya can't go past it!! i'll give them a call on friday.

btw..... i already have a boost guage

half their job is done :cool:

Post by **Spartacus** » Wed Jan 26, 2005 6:43 pm

nice bonnet how much it cost ya

Post by **Vulcanised** » Wed Jan 26, 2005 6:53 pm

Spartacus wrote:nice bonnet how much it cost ya

well........ it cost me nothing........ so far........ i'm told it's worth about $450... i was going to do a small web site for the guy that does them... but as yet i haven't received anything from him to get a start.... so for now, it cost me nothing

Post by **Vulcanised** » Thu Feb 03, 2005 6:33 pm

mickbeny wrote:Hi all...RoeDao,for about $30 you could go to MTQ[turbo specialists] at Warrabrook[2 doors up from Opposite lock] in Newcastle,They will hook up a boost guage and EGT guage and take it for a spin and set accordingly.It will probabaly take them half hour.

I finally got around to calling them yesterday...... they won't tune it because it's not one of their kits :roll:

Said they only tune their own stuff

so i guess i pay through the neck for it. Doesn't really bother me much...... but the handbrake is less than impressed.

Post by **-Richo-** » Thu Feb 03, 2005 7:51 pm

RoeDao wrote:
mickbeny wrote:Hi all...RoeDao,for about $30 you could go to MTQ[turbo specialists] at Warrabrook[2 doors up from Opposite lock] in Newcastle,They will hook up a boost guage and EGT guage and take it for a spin and set accordingly.It will probabaly take them half hour.

I finally got around to calling them yesterday...... they won't tune it because it's not one of their kits Said they only tune their own stuff so i guess i pay through the neck for it. Doesn't really bother me much...... but the handbrake is less than impressed.

Keep us posted mate, im very interested in the outcome!

Post by **dow50r** » Thu Feb 03, 2005 10:20 pm

Hi
Another trick you can do is to run the boost hose of the turbo to after the intercooler on the motor side...that way you will be boosting to the motor what you used to, as the intercooler is a small restriction, there will be less boost at the actual motor now. moving the sensing to after the intercooler takes the intercooler out of the equasion...
Andrew

Post by **-Richo-** » Wed Feb 23, 2005 9:04 pm

Got it tuned yet mate?

Found something interesting on the subject, water to air intercoolers, ARE in Brisbane do them.

http://www.are.com.au/Inter/air_to_water.htm

Post by **rainsey** » Wed Feb 23, 2005 11:19 pm

--------------------------------------------------------------------------------
now that it's intercooled, wind up the boost a little. keep it under 15psi though.

Sorry for sounding ignorant guys, but how do you wind up the boost.

My Rodeo (98 TFS) maxes at around 8-9 PSI (finaly put my boost guage in last weekened), I would be interested to know, simce my model and probably RoeDao's as well, has no engine smarts to do this electronically!!

Also, another question on this topic... in a past life with a non turbo vehicle (would I be embarised to state it was a Leyland TC Marina coupe!) I had a vacumme guage that as you pumped the throttle brought the guage down to 0 mm HG and higher as you were coasting (or maybee the other way around)

My Turbo boost guage on the Rodeo never goes under 0 PSI, i.e obviously always on positive pressure on the manifold. Is this normal?? Not knowing a lot about turbo diesels, should I expect that under a certain RPM, the turbo does SFA and hence I should see some suction in the inlet manafold as the engined opens the inlet valves??

Cheers

Rainsey :oops:

Post by **Vulcanised** » Thu Feb 24, 2005 4:33 am

I still don't have it retuned yet :roll:

i went down to see them on saturday last week, they are going to do some research and call me this week.... so far nothing. On one of the Isuzu forums, there are a couple of guys that had their MU's retuned (with the same engine as mine) and were getting about 368Nm iof torque (225 standard) and up to around 135Kw (72 standard) IF Scott's Dyno Tune don't call me this week, i'll call the deisel specialists in Tamworth and see if they can do it.

Rainsey, the reason you don't get any vacuum is because there is no butterfly assembly on deisels to generate any vacuum. Thats why i put a boost only guage on mine. As for winding up the boost, as far as i am aware the only way you can do it is to increase the amount of fuel that goes into the engine. The wastegate is non-adjustable on the Rodeo. i had a ball bearing in mine, it runs the same boost with or without it blocked.... must be rooted :cool:

Post by **Hoonz** » Thu Feb 24, 2005 7:22 am

RoeDao is that mild steel ur using for intercooling piping?! :shock:

Post by **Vulcanised** » Thu Feb 24, 2005 4:43 pm

Hoonz wrote:RoeDao is that mild steel ur using for intercooling piping?!

ummmmmmmm yeah it's 2" exhaust pipe..... why?

Post by **Hoonz** » Thu Feb 24, 2005 4:46 pm

errr mild steel rusts .... this would go for any one fitting intake pipes out of mild steel(exhaust pipe) .... rust will eventually make it to ur engine
and or worst ur turbo

Post by **Vulcanised** » Thu Feb 24, 2005 4:57 pm

Hoonz wrote:errr mild steel rusts .... this would go for any one fitting intake pipes out of mild steel(exhaust pipe) .... rust will eventually make it to ur engine
and or worst ur turbo

only if you get water in it :cool:

nahhh i am aware of those probs.... and i am planing on stainless pipe... but that costs a crap load more. It will be stable enough until i can afford stainless.

i hope

Post by **Hoonz** » Thu Feb 24, 2005 5:40 pm

ok no worries just checkin don't want ya rig blown up after all the work u done on it ehehehe

:armsup:

keep up the good work

Post by **Vulcanised** » Thu Feb 24, 2005 6:01 pm

Hoonz wrote:ok no worries just checkin don't want ya rig blown up after all the work u done on it ehehehe

keep up the good work

the biggest problem will be not breakin shit when it's retuned.... i hope they can get the grunt that i hear is available

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