Outer Limits 4x4 Board

I own a 2003 SR5 hilux turbo diesel. Just wondering whether anyone has fitted an intercooler to give it a bit more go. I have heard that it is not worth the money as the gains is minimal.
Any thoughts or experience with this would be great.

Thanks
Phil

I think you should do a bit of research on intercoolers and what they do.

Fitting a cooler will allow you to increase your boost safely. Simply fitting one will make it go the other way.

Also look at the fact that they lower intake temps, increasing the life of your engine. I'm looking into fitting one to my 3L, running 13 psi, as my EGTs are a bit high.

I've been pondering the water cooled ones as they are roughly the same volume as the standard plumbing, where as your front mount ones need the boost turned up some to compensate for the added volume of all the plumbing and the cooler, and a BOV in some instances.. The generic water cooled denco kit is $1650.

Keen to hear anyones experiences with the denco water cooled kit....

I've been running the Denco on my HZJ75 for about 12 months. Had it fitted and then put on the Dyno etc. Boost was increased and it leaves all my other mates 75 series for dead.
They come with a very badly designed water fill point which makes it impossible to get completely full and gives you air cavitation. I have fitted a larger header tank which increases capacity and allows you to get all the air out.
All in all, not bad. Obviously decreases temperatures which is good for the engine. Bang for your buck?? Good question. I would say spend your money making sure everything is running properly and dyno tune it. If you still want every last ounce then spend the money.

don't forget with most diesels, unlike petrols, there is no more fuel added when you increase the amount of air going into the motor. most are boost based ie up the fuel depending on boost not the actual amount of air going in.

so with an intercooler it helps squeeze more air in but doesn't add more fuel hence not a big increase in performance. however the increase in effective compression helps make more power and helps overall efficiency.

increasing the fuel to match the amount of air now going in will result in a lot more power. tho you have to be careful pushing the max with air-air intercoolers as the amount of air going into the motor depends on how well its cooled which varies depending on outside air temp and how fast the vehicle is going.

water-air is much better for 4x4's.

the big + with intercoolers is a decrease in EGT's

i don't know much about them but i got one in my GU patrol a top mount one & a mate has one in his GQ patrol there the same engine but he has an after market turbo, mine is factory & his intercooler is a front mount water cooled one, & on take off he easily wins