DENCO Intercooler Help

[XLGXL]

Just bought a water to air intercooler for my 1HDT spoke to denco and they said that the 1HZ fits my model 94 factory turbo. All is fine until I go to fit the barrel, the join between the outlet of the turbo to the inlet of the cast pipe (sought of shape like an S) supply in the kit that goes upto the barrel is not linning up. It is about 40mm out?

Question: Do you or can you rotate the turbo to line up?

Or is the a special cast pipe to fit the factory turbo any advice welcomed

[MUSS]

hmmm i wood give it to greg to have a look jason

[udm]

Just bought a water to air intercooler for my 1HDT spoke to denco and they said that the 1HZ fits my model 94 factory turbo.

Or is the a special cast pipe to fit the factory turbo

Its a bit confusing... do you have a 1hdt or actually a 1hz with aftermarket turbo?

[BeerCruiser]

They have supplied you with the kit that is used for 1hz after market turbo, not factory turbo. I don't think denco even make a casting for that barrel intercooler to factory turbo.

Most ater market turbo kits for 1hz motors have the turbo outlet pointing pretty much vertically up. The factory turbo outlet is angled towards the engine.

To rotate the compressor housing on the toyota CT26 turbo to a different position is not an easy task. First you will need to remove the turbo.

The biggest problem is that the wastegate actuator is mounted on the compressor housing so by repositioning the housing, the wastegate actuator rod will be out of alignment, this may change boost control (these wastegate actuators are NOT adjustable) & you will need to reshape the rod to get the correct alignment. Another option is to fit a different adjustable wastegate actuator.
To rotate the housing there is an alignment pin on the turbo body and alignment hole in the compressor housing. You will need to drill another alignment hole in the compressor housing to get the desired compressor housing position or just remove the alignment pin. This part would not be too difficult.

My suggestion is to get denco to supply you with a correct casting.
I think it would be quite a severe 'S' shape as that barrel intercooler hangs out quite a bit.
Keep us informed as to denco's responce.

I am in the proccess of fitting an intercooler on my 1hz motor that I fitted a factory turbo from a 1hd-t a while ago. I am going for a air/water intercooler as space is a premium under bonnet of HZJ75.

Looked at the denco setup but found pressure drop too much and poor cooling efficiency.
Denco only manufacture the adaptors on either side of intercooler and brackets for front radiator, the rest (barrel, front radiator etc ) are PWR components. I was not very impressed by denco's responce when I started asking some quite technical questions about their air/water intercooler, they either did'nt know or did'nt want to tell me much.

If you want some serious info on air/water intercoolers have a look at http://www.are.com.au/ , if you speak to Richard he will give you a rundown about these barrel intercoolers and other options, he is extremely helpfull. I am getting an air/water intercooler core (best available by far) from them and will be manufacturing the rest myself.

Hope this is helps

[XLGXL]

Sorry about that I have a 1994 factory turbo 1hdt rang denco to discuss putting an intercooler on because i was confuse myself as they don't do a 1hdt intercooler but I was told that the 1hz will fit on the 1hdt no problems

Wel with the kit just about on barrel in and then you go to place the pipe that goes from the drivers side of the barrel to the turbo and it is out of alignment by 40mm now I could go out and by a flex hose and bend it slightly to fit or rotate the turbo slightly unsure

I might just ring denco tomorrow if they work Saturdays they probaly would as every else has to to keep on top of the bills

[XLGXL]

Thanks BC That does make alot of sense as you were spot on with the shape. After looking at the break down of the turbo I have relized the big task for the little job is way overboarded so I will probaly go with the option of a flex hose from the turbo outlet to the bottom of the pipe that came with the kit and see how that goes

[XLGXL]

Ok so it is on I use the oringanl hose that went from the turbo to the original inlet pipe which gave me a bit of flexability as for bleeding the system not as easy as I thought the pump moves the water very slowly. If you are at the front of the car it goes in a anticlockwise diretion (I think)

As for the improvement that will have to wait until it is on the dyno which I will get in the coming weeks I have only just recently had it dyno so I can now compare the difference

[XLGXL]

Ok so I spoke to Denco and was informed that the pipe does need a bit of bending to fit. It is easier to use the OEM rubber hose then the one supplied from Denco you will also need better clamps to hold the hoses on, the clamps supplied are of not good quality. I was informed that when the kits were first made there wasn't a big market for the 1HDT (I think safari had the market then) over the 1HZ.

I was told today that in the near future that a cast intake pipe for the 1HDT factory turbo will be manufacture. Also when you bleed the system to have the flow of the coolant going in the opposite direction to the intake flow.