Outer Limits 4x4 Board

Saw these on here a few months ago now, www.frozenboost.com Intercoolers. Not too many people running them, but apparently they fitted into the GQ (with aircon) fairly well, so I decided what the hell I'll buy one. Great mob to deal with, will answer emails very promptly and were not hesitent at all to sort out the drama of forgeting to send the pump with the kit! But with no questions asked the pump was in transit the next day after querying them about the mix up.

Quality looks decent, and the price is fairly appealing to about $550 US for all the gear you need, time will tell.

Now the fun begins, trying to fit the bloody thing into the vehicle.

First up the radiator is awkward due to the lines for the aircon (not sure if every modle is like this my GQ is an 89), also the bonet catch needs trimming with the grinder along the bottom.[img]http://i498.photobucket.com/albums/rr34 ... ge0015.jpg
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Fit in, but grill requires some trimming. Used the angle grinder to trim the bottom off grill, and the a dremell to remove plastic from inside the grill. Will also have circular sections removed for the rear of the thermo fan motors. (I'll post pics later of the finished result).
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Now temp fitted the intercooler, its a type 3. same side 700cfm unit. Bought the silcon elbow off the site too, cheap as chips compared to Super-Crap.
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3" to 2.5" reducer, probably could go a 3 to 2.75 tho. Pain in the ass to fit, stretched heaps.
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Hopefully the week after New Years, will have it all finished and give it a run to record some egt's, and charge intake temps.[/img]

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while your at it mate, id go and get yourself a GU air box from either a ZD30 or an RD28t, it will give you heaps more room without the cast air box sitting over the motor,

ozy1 wrote:while your at it mate, id go and get yourself a GU air box from either a ZD30 or an RD28t, it will give you heaps more room without the cast air box sitting over the motor,

I agree! And post pics of how it all fits in with your dual batteries!

watch your engine temps closely with all that clobber in front of the radiator and probablly a boost/fuel increase plus winch, spotties and bar already there!!

Feenz, perfect timing - I've just bought a kit from ebay for my 89 TD 42 and will be fitting it in the NY. Only difference is I'll be fitting a high mount turbo and a Donaldson, rather than having that big air filter casing on top of the engine.

A question - did you leave the fan in front of the aircon condenser or move it to the FB radiator, seeing as there are 2 mounted there?

And did you get a remote filler cap in the kit?

Look forward to watching your efforts. Thanks in advance

coxy321 wrote:

ozy1 wrote:while your at it mate, id go and get yourself a GU air box from either a ZD30 or an RD28t, it will give you heaps more room without the cast air box sitting over the motor,

I agree! And post pics of how it all fits in with your dual batteries!

i run the ZD30 air filter housing with duel battries, depending on your battry tray its either bolt up or mod stuff,

with ARB tray, which i have, i had to move the tray rearward about 50mm, this also incolved reshaping the inner guard to suit the shape of the overflow bottle as its an odd shape, but once done it was sweet,

Yeah I'm tending toward the idea of the 3.0L airbox, but it wont be just yet, as I'm planning to a heap of camping this summer instead of tinkering in the garage.

Yes I did get the remote filler cap, I'll put up some pics in the next few days, as I've been welding and drilling brackets today (getting close to being finished) and just started to fit all the plumbing. As for the aircon fan, its a crap little 7", so one of those larger fans will come into play in the aircon elec. circuit as well as for the intercooler system.

Any ideas on that? Does that little aircon fan serve much purpose? Never seen my one on, so im assuming it's temp activated??

Should have it done after Christmas now, nearly finished.[/quote]

Feenz wrote:Any ideas on that? Does that little aircon fan serve much purpose? Never seen my one on, so im assuming it's temp activated??

It is supposed to come on as soon as you put the AC on. You would be surprised how much the little stock fan helps the AC system transfer heat. When your car is stopped (in traffic or whatever), there is bugger all air flow, and the AC system can only cool down in direct relationship as to the heat it can dissipate on its hot side.

I've never seen either of mine on, either.(I've got 2 GQs) Must have a bit of a poke around.

Feenz, on Patrol4X4.com I've started a thread on this topic and the suggestion was made that the frozenboost system will be hard to bleed because the inlet and outlet are half way down the ic. Have you thought/done anything about that?

I was having a think about that last night over a few beers. One way would be to drill a hole in the top at one end and tap it, then just pump through fluid with the vehicle jacked up a little at the appropriate end. Or even easier is once every thing is hooked up, stand the intercooler vertical and bleed it back to the remote filler. Im tending toward the adding a plug on top so it can be checked occasionally without having to unbolt the intercooler.

does your truck have a body lift?

Yeah it's got a 2" body Lift. Should have mentioned that, looking at it I don't think it would fit in without it.

some of the other coolers they do should be able to fit,
mine doesn't use the same air filter setup as yours, so i'd have room back there.

Any updates on this? Grille trimming? Cauz it sits a damn long way out, was hoping to see how much needs to be "trimmed"

marin

Well put it all together on Monday, took it for a drive and the injectors let go. They're 90K old and non-turbo spec I think, buckets of white smoke (not the turbo seals). Renew them next week hopefully. So no 4B'ing up at Cairns as planned. And it's the raining non-stop with mud everywhere, so just got back from doing the touristy stuff with the missus instead.

So far, minus one braket and a tapped bleed plug. The L/H thermo will fit without trimming but it's a piece of crap compared to the R/H Davies craig 10", which required trimming. It was a massive PITA so I just cut out a rectangle section between the out verticle ribs, will make a custom screen later. Also that's a Johnson 550GPH bilge pump, as the kit one still hasnt rocked up.





The little copper elbows are $3 from Bunnings.



Oil seperator, to keep out the blow-by from the cooler.

Feenz wrote:Well put it all together on Monday, took it for a drive and the injectors let go. They're 90K old and non-turbo spec I think, buckets of white smoke (not the turbo seals). Renew them next week hopefully. So no 4B'ing up at Cairns as planned. And it's the raining non-stop with mud everywhere, so just got back from doing the touristy stuff with the missus instead.

So far, minus one braket and a tapped bleed plug. The L/H thermo will fit without trimming but it's a piece of crap compared to the R/H Davies craig 10", which required trimming. It was a massive PITA so I just cut out a rectangle section between the out verticle ribs, will make a custom screen later. Also that's a Johnson 550GPH bilge pump, as the kit one still hasnt rocked up.

Oil seperator, to keep out the blow-by from the cooler.

Um injectors dont just let go? weird

And how do you get blow by oil in the IC coolant?

Yeah I'm no diesel specialist by any means, but a friend that is was fairly convinced an injector or a few are on the way out. The injector pump is on 50K out of rebuild and turbo seals are fine, engine has done 90K, not much else it can be. It smokes under boost and at idle (white). As for the oil seperator it's on the EGR line from the rocker cover, as blow by gets into the intake and oils the internals, meaning the air core of the intercooler may be therotically less effiecient, I just don't want to clean it really.

oh that filter is on the PCV oh right my mistake.

Hope the injector issues arnt too expensive for ya mate.

Good luck

Feenz, it just might be that filter on the hose from your rocker cover causing that white smoke. I fitted a catch can into that line on my ute because the suction from the turbo was sucking oil vapour into my turbo etc and as soon as I fitted it, the engine started blowing heaps of smoke, especially at idle. Took it out, smoke stopped. Gotta be worth a try, eh?

Thanks for the photos, BTW. Very useful. It looks kinda mean with that hole in the grille, I gotta say...

I'm going to try and space my grille out a bit, rather than cut it up. We shall see.

definatly could be the pcv they are sensitive things on nissan diesels they hate too much back pressure

when i got my old wagon it was vented to a tube that dumped oil onto the front tail shaft so i tried to put a catch can on it and it pumped white smoke so i took it off and left it as it was problem solvered

Yeah, thanks very much guys, wasn't really thinking down those lines, will try in the morning. Which hopefully works, as forking out the money for new injectors wasn't making me smile.

Cheers.

Yep it was the moisture trap. Problem gone
34* 70% humidity today, normally fairly slugish before, now it just powers through, the only thing holding it back is the flow. I've got a 2.5" exhaust with squashed bends, fixing that up through the week. Dragged a new 3L Hilux neck and neck on 35's to about 90km/hr and had to slow down. Time to get a temp probe.

No probs with the pics Burra, just give me a buz if you want anything else specific.

awsome stuff feenz

That's fantastic, Feenz, so glad I was able to help. These forums are definitely the duck's guts!!!

How did you end up bleeding the IC? And I assume you are pumping from the bottom of the radiator, yes? And how did you wire up the pump and fans - are you using a thermal switch to trigger it when it gets to a certain temp?

So what exactly was the difference you've noticed with the IC fitted?

Can't wait to get into mine - just gotta finish a few earners I've got going ATM....

Yeah your not wrong Burra, the forum is a good thing, helps so many times.

Yep it's pumping from the bottom, those bilge pumps wont pull water they only push it from a head of pressure. ATM the fans are on a switch and the pump is relayed to ignition. Waiting to finish holidays then I'm going to fit an air temp probe and water temp probe, then will test for abit. Most likely I'll use water temp to trigger the fans.

Primming was a bitch, had to tilt the whole unit vertical and bleed from there took a while to get the air out, and im not sure if its 100% gone. Im going to put a bleed/fill plug on top soon.

Over all makes a fair bit more power, 35's were abit sluggish before, now it's like being back on 33's with more pull at 7-10psi. Awesome straight line power offroad, it's raining heaps up here and on a dirt track spins the wheels though every gear.

Here's some better pics of the grill, I don't think it looks too bad.
Any ways good luck.

Thanks for all your efforts, Feenz. Much appreciated.

It'll be a while till I get onto mine but I know a lot more than I did before. Would you mind posting details of your wiring setup when you've finished it? I was planning on using one of those Jaycar thermo switches on the IC body to trigger the pump and fans, plus possibly fitting a temp gauge into that hole at the bottom of the rad to keep an eye on things.

Cheers M8

Hey,

Nice work.... A lot under-estimate the potential of these coolers....

I have one on my turbo petrol powered Mav. I have the Bosch pump and only one fan, and even that's noisy as f%@k.

Do you get much heatsoak sitting over the motor??

Cheers

Daz

Yeah it's getting heaps of heat soak, although the radiator inlet is very hot and the bottom section is cold and the air flow at rear isn't that warm, probably over-kill. lWhen I get back to work I'll knick some turbine heat sheild, its awesome stuff, should fix that. Anyway just got back from towing the boat up the coast along the beach, all that I can say is it hauls ass now, doesn't get hot on the sand anymore. Massive difference, very impressed, awesome improvement in power/for-money.

Just finishing up Marin's intercooler install.

We used a late Telstar radiator with custom end tanks and Spal 55m slim line fan and keep the grill intact by folding the top lip down on the cross member.

















Full install here.
http://www.patrol4x4.com/forum/showthread.php?t=24057