Intercooler on a 2.4

[JCEv39]

I'm trying to find info on fitting an intercooler to a 2.4 without making massive mods (i.e. I don't want a 2+" body lift). There seems to be next to no room in front of the radiator on mine (AC condenser and dryer in the way) and short of fitting one underneath I can't really see where it'd go. I've found a small selection of water cooled ones but nothing that immediately screams as being suitable (although one for an MX5 I think should go in place of the current aluminium boost pipe across the top of the engine but finding details is proving tricky!).

Your views please (and any pics more than welcome) as it currently offends my engineering sensibilities to be putting air into my engine at 100+°C!!!

Thanks in advance

JohnE

2.4 SSR-G

[RMS_CLK]

Have been looking at this myself. Chargecoolers are not great because you need a completely separate water system for them - too much hassle so im going for an intercooler. Im probably gonna mount it underneath with some wire mesh to protect it from stones. Gonna use a 2wd cosworth intercooler. Its quite deep from front to back and wide, seems the right shape to use.

[dirtydog]

why dont you mount it on top?

[JCEv39]

On top? If you mean on the engine, there really isn't much space and I've yet to find an intercooler that thin enough without a) a body lift and b) cutting a whole in the bonnet, neither of which I want to do. You also get a significant amount of heat soak when running at low speed (my old Legacy used to retard the ignition like mad when in town).

I have been thinking about mounting an air/air in the place of the current air filter canister and ducting cooling air in with a fan from behind the head light but that seems as complicated as fitting an air/water chargecooler. Allard Turbosport seem to do a nice compact air/water chargecooler for around £300 which looks like it would be perfect but I'm still waiting to hear back from them.

Will keep the list posted when I sort something out.

Cheers

John

[computingfuture]

I cut a whole in my bonet. I have yet to fit a scoup but it worked ok. The only problem I now have is how lean it runs, its gunna run me about £320 to get the piggy back ecu upgrade.

[dirtydog]

so you just have an open hole?

[computingfuture]

so you just have an open hole?

No its filled with an intercooler slanted at about 30 degrees.

[dirtydog]

[silvtr1000]

Those crazy Ozzies, eh? Mind you, they'd have more call for cooled air than us...

http://www.toyotasurf.asn.au/techsit...ngtopmazda.htm

http://www.toyotasurf.asn.au/techsit...coolingtop.htm

http://www.toyotasurf.asn.au/techsite/intercoolingf.htm


Mark

[JCEv39]

computingfuture,

Erm, don't worry about your diesel engine running lean. All it means is that you CAN put more fuel in if you want (which is pretty much all the piggy back boxes do) unlike petrol engines where you NEED to put more fuel in to prevent detonation. After all diesel engines run on detonation (controlled but thats essentially the method for starting combustion!).

Having an intercooler will make your engine much more efficient (as it'll be using cooler, more dense air i.e. generally more of it too!) and less prone to cylinder head problems as the average in cylinder temperature will be reduced. If you're remotely interested in the environmental issues, you'll also be reducing your NOx emissions due to the generally cooler combustion and probably reducing your particulate (i.e. smoke) to boot due to having a greater mass of air per unit of fuel.

Any chance of some piccies of your install (even though I really don't want to cut holes in my bonnet!!!)?

silvtr1000,

Thanks for the links. I'd seen one of them before (the one with the beared bloke looking rather too excited about mutilating his bonnet! ). Both the top mount ideas highlight another problem I hadn't considered with this arrangement - how do you top up the oil? The front mount installation was clever but how much pipe? I still think a air/water chargecooler is the most efficient way forward, I just need to find one I can measure (Pace and Allard make them and they were standard fit on Subaru RS legacys, Toyota GT4s and Bentley Turbo S!!). An option I'm also considering is trying to find an IC I can duct air to (probably the easiest soluction) either from behind the head light or from beside the radiator but I need to work out a way of getting rid of the "waste" air (underbonnet airflow is a notoriously complicated thing to predict!).

Anyway I'll keep the forum posted!!!

Cheers

JohnE

[andy]

John

A couple of pictures of the standard intercooler for you, if you need any more give us a shout.

[JCEv39]

Thanks Andy,

I take it those are from a late model 3 Litre surf. The oil filler point is right at the front of the rocker cover so you can check / fill the oil without removing the IC (a real problem for me as I do about 500miles per week and so need to top up the oil regularly!!). Going to have a look at a few types of IC tonight so will report back. By the sound of it there are a number of people interested in fitting one so if I ever get something sorted I'll publish the plans / fitting instructions.

Cheers

John

[dirtydog]

good ol' boy - would be good if you find a decent size one that will fit with no body lift.

[marky]

Thanks Andy,

I take it those are from a late model 3 Litre surf. The oil filler point is right at the front of the rocker cover so you can check / fill the oil without removing the IC (a real problem for me as I do about 500miles per week and so need to top up the oil regularly!!). Going to have a look at a few types of IC tonight so will report back. By the sound of it there are a number of people interested in fitting one so if I ever get something sorted I'll publish the plans / fitting instructions.

Cheers

John

500 miles a week & you have to top oil up. Mine never uses any between oil changes

[kitesurf_phil]

computingfuture,

Erm, don't worry about your diesel engine running lean. All it means is that you CAN put more fuel in if you want (which is pretty much all the piggy back boxes do) unlike petrol engines where you NEED to put more fuel in to prevent detonation. After all diesel engines run on detonation (controlled but thats essentially the method for starting combustion!).

Having an intercooler will make your engine much more efficient (as it'll be using cooler, more dense air i.e. generally more of it too!) and less prone to cylinder head problems as the average in cylinder temperature will be reduced. If you're remotely interested in the environmental issues, you'll also be reducing your NOx emissions due to the generally cooler combustion and probably reducing your particulate (i.e. smoke) to boot due to having a greater mass of air per unit of fuel.

Any chance of some piccies of your install (even though I really don't want to cut holes in my bonnet!!!)?

silvtr1000,

Thanks for the links. I'd seen one of them before (the one with the beared bloke looking rather too excited about mutilating his bonnet! ). Both the top mount ideas highlight another problem I hadn't considered with this arrangement - how do you top up the oil? The front mount installation was clever but how much pipe? I still think a air/water chargecooler is the most efficient way forward, I just need to find one I can measure (Pace and Allard make them and they were standard fit on Subaru RS legacys, Toyota GT4s and Bentley Turbo S!!). An option I'm also considering is trying to find an IC I can duct air to (probably the easiest soluction) either from behind the head light or from beside the radiator but I need to work out a way of getting rid of the "waste" air (underbonnet airflow is a notoriously complicated thing to predict!).

Anyway I'll keep the forum posted!!!

Cheers

JohnE

I saw a Surf on a Japanese site and the cold air feed was from the n/s indicator cluster. In fact the n/s indicator had been removed altogether to make a convenient hole. Useless info because, I guess, this was a dedicated off roader!