callum Posted September 5, 2006 Share Posted September 5, 2006 following on from a brief discussion in a thread inhe international forum about diesels, here's some pics of the intercooler in installed over the last couple of days. its raining heavily again, so i'm a bit bored. i post i here, becuase whilst its in place its not plumbed in yet and i might need some help tech content is a bit lame i'm afraid, not too tricky just time consuming. and with a tendency to snowball. i'll also apologise for some of the welding in advance. hopefully you cant see it too well in the photos but i'm just learning and finding 2mm steel a bit difficult with the arc welder. nothing structural though so its ok. installation is a bit more difficult than with tdi's as with a tdi, you can just bite the bullet and buy an intercooler that fits in the space, and plumb it in through the space vacated by the old intercooler. unfortunately this one's a bit more difficult as i'm running an isuzu 4jb1, which didn't come with an intercooler from the factory. the intercooler is an ebay special. i went looking for a saab 9000 one and found the one i have, a saab 9-3, which i got for i think £30 delivered, not bad for a brand new, never fitted intercooler still in its original saab box. i had emailed the vendor, to find out how big it was, '40x30 cm' i was told. ok i thought, i'd like bigger, but at least i wont have to move the rad or anything. alas when it arrived it was huge, about the same surface area as the radiator, but with tanks on each end, making it a bit wider overall. i thought i'd give it a shot anyway though and see if it could be fitted. alas summer holidays ended, so i ended up waiting about a year after fitting the isuzu engine beofre giving the intercooler a shot. holidays wil end again shortly, but hopefully it will not remain an engine bay ornament for a long time here's it in place and here's what it will be hooked up to its quite big and sits where the radiator used to sit radiator has been moved back 60mm, which seemed like an easy thing when i first decided to do it, but i had to cut up brackets, make some, new ones. had to switch the bonnet stick round too, but it sits abtit funny now as it was raining so i measured it rather hastily. i also had to cut some holes for the tanks and for plumbing. again i thought it would be easy, but there's two skins on the inside of the wing and other reinforcement., so i tried to take out as little as possible a run of grommet strip and the tanks poke through the wings. bit of a **** picture, but you can see its a very tight fit.wings are crow barred up as high as they'll go with the existing holes and the cooler can just move back and forth when the clamps are not in place at the top bits of tesco bags are keeping the dirt out. here's an in bay image, got to get pipes under the top hose and air intake and then into the cooler. probably have to move the power steering flask thing. aat the bottom wher the rad is moved back, there is not much clearance between rad and power steering box. i have the hose in at th emoment, but its slightly squeezed and makes a bit of a hard turn out of the radiator. if it proves aproblem i'll get a 90 degree exit brazed on. current plan for plumbing is literally plumbing materials. i can get my hands on copper pipe and various solder joints easily enough. it comes in good sizes, matching the diameter of the inlet manifol perectly and available in a size really close to the intercooler outlets. there's lots of solder on angles and downsizing bits as well so it shouldn't be to difficult to assmble. most importanlty its cheap. i'll need silicone hose to take the sharp turn out of the intercooler and i think i'll just use radiator hose to join the other end and also make joints for disassembly and to give the assembly a bit of flexibility. i can get rad hose from my dad's work for not too much (not 90 degree bends alas ). so there it is, rather dull and simple tech. wouldn't mind any opinions on the matter if anyone thinks i'm taking the wrong route. Quote Link to comment Share on other sites More sharing options...
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