KZN-130 Intercooler install

[Blizzard]

Hello,

I wanted to show how we did the intercooler install on my 3.0TD 4Runner.

This is the intercooler used, from a Mitsubishi Pajero 2.8:



Also bought some constant radius SS bents:



As I don't have a body lift, we chopped the top of the valve cover and used some aluminium sheet to cover the hole.

Also we fabbed some beefy brackets for the intercooler:





Tacking the piping. Notice the radius of the pipes is constant:





Turbo exit piping



Intake entrance / Intercooler exit piping







Tacking the intake flange



Fabbing the intake flange



We changed the intake rubber hose for a different one. It has steel wire to prevent squeezing



Finished intake flange







This metal tube addon is temporal

















This week we'll be installing the hood scoop and padding around the intercooler.

All of this was complemented with a 70mm SS exhaust with constant radius bents and an injector and pump rebuild.













Hope you like it.

David

[POPEYE]

Excellent work my friend, i'm always in awe for your frabrication (and workshop facility) i wish!!!! i certainly could do with you here regarding the exhaust, i'm going to try sticking together a 3" s/s one soon, i was reading your post on Yotatec a while back, top work mate, keep it comeing,
btw did you ever stick the leds in the instruments???

[Apache]

Looking good.

Do you have any drawings / dimensions of the intake flange assembly you fabbed up? Thats the only bit I'm short of to do mine.

In fact, if you have dimensions of all of the parts (pipe fabs etc) that would be a great help to those doing the same mod.

Cheers

[Blizzard]

Hello,

I'm glad you like it.

I don't have drawings as we made it along...

The flange it's quite easy, just begin with a square piece of metal (We used 10mm one) and begin grinding, it's not necessary to grind for fit, only for looks.

This is the shape of the intake flange. Be careful because we broke mine when undoing it for rebuilding the injection pump.



David

[europa88]

Thats a really cool installation!

Just one thing I cant make out from the pics is how the throttle cable is attached and works? Or is it fly by wire?

[europa88]

Doh!

Just realised It's a lhd 4runner!

I think the 1kzte Surf is trickier to do because the throttle butterfly is in the air intake housing.

Any one any further on with intercooling a 1kzte in a 2nd gen?

Andy??

[Blizzard]

Yes, my 4Runner has a 1KZ-T not E hehehe

David

[stormforce]

Yes, my 4Runner has a 1KZ-T not E hehehe

David

its only the imports ain't it that are the kz-te and the 4runners kz-t
hows the truck coming on Dave

[Blizzard]

It's a strange thing, I've seen 4Runners that have the 1KZ-TE in Germany but all the 4Runners sold in Spain where 1KZ-T's... We never got autos too...

David

[europa88]

David

It's the same in the uk, all 4-runners were 1kzt's (apart from the petrol v6)

Manuals were the usual and though I cant remember clearly, I believe the odd v6 auto found It's way into the Uk in the early to mid 90's.

[Blizzard]

Hello,

We picked up the truck from the body shop. It rained mud so the truck is dirty but you can see how awesome the 2008 Hilux hood scoop looks on a Surf:











Hope you like it.

David

PS: The truck is f*ck*ng powerful now, the hood scoop made a huge improvement in engine power!

[RodLeach]

Looks amazing!!

I wanted to fit that scoop.. but i'd need to do an intercooler first..

Awesome having you here btw mate, you do great write ups!

[Blizzard]

Hello,

Just noticed I didn't post pics of the valve cover mods.

Here they go.

The valve cover it's some kind of hard plastic, remove it an clean it.



Trimmed it in two stages, better to cut twice than to regret once!



Then file the cut so it is perfectly even



Present the alu sheet over the valve cover and bolt it using two previously existant holes



Then begin trimming. A small tool like a Dremel is very handy here

You can also see the holes for the new bolts



The tube that picks the gases from the valves was trimmed facing to the engine



Added a small tab with a rest of the valve cover trimmed to allow the alu to rest against it and also to put a bolt. Glued it with epoxy





Finished and clearanced valve cover



Here you can see the space that is now available





David

[Blizzard]

Hello,

I've new pics with the truck clean.











Cheers,

David

[Apache]

Browsing and came across this thread again.

Inspirational, and top class engineering!

Are you still around David? What state is the truck in these days?