nathan Posted September 21, 2006 Share Posted September 21, 2006 I've bought a Td 5 intercooler to go into my 200 tdi discovery and wondered if anyone else has done this conversion, how they did it, what pipework you needed and where you bought it from? Basically any ideas, suggestions and advice greatly appreciated. Cheers, Nathan Quote Link to comment Share on other sites More sharing options...
Andy Posted September 21, 2006 Share Posted September 21, 2006 is the Td5 intercooler bigger then? ive never seen one. zorst pipe & various bits of rubber hose will mean you can plumb anything in. Quote Link to comment Share on other sites More sharing options...
nathan Posted September 21, 2006 Author Share Posted September 21, 2006 I checked the measurements before buying one and this was the information I got ,THEY ARE 24 INCH CORE 29 INCH OVER ALL ,9.5 INCH HIGH 2 INCH DEEP WITH 50mm OUTLETS. Quick calculations are STANDARD IC total size (width x depth x height) 221.61 inches TD5 IC total size (width x depth x height) 456.00 inches STANDARD IC frontal area (width x height) 80.58 inches TD5 IC frontal area (width x height) 228.00 inches cheers nathan Quote Link to comment Share on other sites More sharing options...
Andy Posted September 25, 2006 Share Posted September 25, 2006 sounds nearly as large as the aftermarket one ive got. id say go for it & bodge the pipes up somehow. i fitted the new intercooler in the only place it would go & then sorted the pipes out. i dont know how well the inlet/outlet line up compared to the normal intercooler. all i had to do was slice the original pipes in half & insert bits of 2" zorst pipe to extend their length. Quote Link to comment Share on other sites More sharing options...
nathan Posted October 17, 2006 Author Share Posted October 17, 2006 Ok done it Theres a few pics here showing the cutting involved, the top fixing points and the use of all the original pipework being used. Total time for conversion about 4.5 hours Parts required=intercooler, 2x 90 degree silicone bends cut down, small lengths of 2" stainless steel tube and 11mm tube and a few jubilee clips. Tools required=angle grinder, hacksaw, screwdriver, tape measure, welder, 13mm spanner or socket. Nathan Quote Link to comment Share on other sites More sharing options...
geoffbeaumont Posted October 17, 2006 Share Posted October 17, 2006 Nathan, your image link is broken (missing the opening img tag and and extra closing url tag) - you also can't use an image URL with no extension, it has to be .gif, .jpg or (I think) .png Had a look to see if I could fix it for you, but unfortunately the image is also on a site you have to log in to so we wouldn't be able to see it anyway! Quote Link to comment Share on other sites More sharing options...
nathan Posted October 17, 2006 Author Share Posted October 17, 2006 Hang on a minute. Quote Link to comment Share on other sites More sharing options...
nathan Posted October 17, 2006 Author Share Posted October 17, 2006 Geoff hope its fixed now, can youlet me know? Nathan Quote Link to comment Share on other sites More sharing options...
waveydave Posted October 17, 2006 Share Posted October 17, 2006 Dose it make it go any better then? Be interested as for some funny reason i might just have a few of those kicking about and my 300tdi needs some more ooooomphh.And as im a skinflint i dont want to spend any money doing it Quote Link to comment Share on other sites More sharing options...
geoffbeaumont Posted October 18, 2006 Share Posted October 18, 2006 Geoff hope its fixed now, can youlet me know?Nathan Was slightly screwed up still but worked - did a bit of a tidy up and stuck an image back in (had to guess at which one you wanted). Hope that's pretty much what you were aiming for Quote Link to comment Share on other sites More sharing options...
nathan Posted October 18, 2006 Author Share Posted October 18, 2006 Thanks Geoff. Waveydavey, I was expecting only 3-5 bhp more so the ic alone isnt really gonna make a difference to performance. I have done the ip adjustments though and thats made a big big difference. I have found that since fitting the ic I havent reached peak boost but have found that the weld on the u-pipe is blowing very slightly so i guess this is where the loss of boost is coming from. Quote Link to comment Share on other sites More sharing options...
STUBBY Posted February 12, 2007 Share Posted February 12, 2007 Nathan have you noticed any increase in engine temp with larger intercooler blocking more of the radiator, did you also remove the existing intercooler, as it isnt clear in the pictures. Quote Link to comment Share on other sites More sharing options...
Andy Posted February 12, 2007 Share Posted February 12, 2007 i found my 200tdi runs about a needles width warmer on the guage with a fullwidth intercooler blocking the rad. however it doesnt get warmer when climbing hills etc so overall i run cooler, at least it never reaches the highest temps it used to reach. *all answers apply to when the damn thing is working properly Quote Link to comment Share on other sites More sharing options...
nathan Posted February 26, 2007 Author Share Posted February 26, 2007 Its been a few thousand miles now since doing the conversion and i'm very happy with it still. I've increased the boost to 16psi and increased the fuelling too Heres a few pics of the job done. Quote Link to comment Share on other sites More sharing options...
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