Hi David,

Nice article, thanks for taking the time to add it.

I am happy out I insert it in the project power thread so that it gets the visibility it deserves.

Furthermore it should go in technical articles so PM admin and let them sort it out.

Regards

Ron

 

Introduction
This is a summary of https://www.redlineforums.comTHREADs
The 88bhp (AJT - Blue I) engines are essentially identical to the 102 and the 150 except the injector specification, the intercooler and the engine mapping.
Charge air coolers increase the efficiency of engines under high sustained load by increasing the density of the air entering the engine - offsetting the heat from the engine bay and the heating effect of the compression in the turbo (about 1 bar after a remap). This puts significantly more oxygen into the cylinder and giving a bigger bang with less fuel.
This modification will not do anything at low speeds or low-boost conditions and will be pretty marginal without the other upgrades.
The is no need to increase airflow as this is only relevant at speeds over 20mph and therefore the ducts will supply adequate cooling.
There is no change to any mechanical systems so it will have no effect on engine revs at a particular speed - 5th gear mods are available.

Layout

This is the basic layout we are aiming for in both Long and Short nose version.
This version eliminates the sensor pipe shown right and connects the I/C directly into the original elbow on the inlet

Things you’ll need
1 - Mitsi Intercooler (Pajero, L200 others - source ebay/scrapper)
4 - Anti-vibration mounts - M6 (ebay)
M6 fasteners and washers

Brackets and Ducts
No code has to be inserted here.
Damping Clip - 701863841

Pipes (starting at turbo)
A - 54mm 90 elbow (original)
B - 45mm straight (comes with cooler)
C - 45mm 180 silicone elbow (ebay) - cut short on the IC end J-shape
D - 45mm 180 silicone elbow (ebay) - cut short on the IC end J-shape
E - 54mm 90 elbow (original)

Couplers
A-B - 54-45mm Alloy reducer (with flanges) (ebay)
B-C - 45mm Alloy coupler (with flanges) (ebay)
C-D - 45mm Intercooler (ebay)
D-E - 54-45mm Alloy reducer (with flanges) (ebay)

Clips
A, E = 2x Jubliee Clips (come with cooler)
B, C, D = 6x 52mm - 55mm T BOLT CLIPS (ebay)

Install Sensor into Intercooler
Installing the sensor directly into the cooler saves your original inlet sensor pipe if you want to reverse the mod.
1 - Bore out existing hole
2 - Drill and tap fasteners for VW sensor
3 - Seal with rubber or sealant

Install Bonnet Ducting and Brackets
Short-nose

Long-nose

Matching the bracket to the Intercooler
The holes don’t match so you’ll need to match them up - 6mm drill.

Bending the brackets
Install both brackets
Attach the anti-vibration mounts to the intercooler
Applying firm pressure with both hands bend the lower bracket down until the I/C fits easily.

Pipework
Trim the U-bends so that the straight part is as short as possible onto the intercooler - this gives more clearance to the bulkhead
Remove the original plastic inlet pipe and keep
Fit the reducers to the Turbo and Inlet - leave clamps loose
Assemble remaining pipework and trim as needed

You’re Pretty Much Done
Just tidy up and go get a remap
Better still get some ProjectPower2 injectors before the remap

Other Projects
EGR - Blank
Inlet clean
PP2 - https://www.redlineforums.comthreads/51256/
5th Gear thread - https://www.redlineforums.comthreads/83109/
Remap

• Chipwizards (Rochdale) - Wayne Schofield cappuccino34@hotmail.co.uk
• WagenWorx (Somerset) - Nathan Johnson http://www.wagenworx.co.uk
• Pendle Performance (Lancs) - http://www.pendleperformance.com/

 

Brilliant write up must get mine done had the l200 intercooler sitting in the garage for too long now T:

 

I have been trying to track down the relevant couplers and reducers via ebay and google in general, and I can't find a single thing. I've tried various spellings and word combinations to no avail. I find this incredibly surprising and feel like I must be malfunctioning!

Does anyone have a link to the relevant items on Ebay?

 

http://stores.spencerashley.com/45mm-54mm-alloy-pipe-reducer-for-silicone/

 

is there anywhere else that does those couplers, had to start a paypal dispute as no joy with communications for non delivery..got a refund but still need couplers???

 

I wish someone could provide a kit for this !

Would be great !

 

We looked in to this and the cost is actually prohibitive. The end result would cost a simialler amount as a second hand VE OEM one.

 

I'm struggling to find the 54-45mm reducers the link above doesn't work, Peppers performance is the only place i can see list them but they are out of stock, and haven't replied to enquires

 

So I've got the cooler and the mounting plates and the bonded bushes, but the cooler fouls the bonnet???what am I doing wrong?

 

Ok so I've removed the Mitsi fan and flipped the cooler over and now it fits a lot tight but fits. bear in mind that this is on the short nose van, obvs long nose will have more room depending on which brackets you choose.

 

Right guys anyone thinking doing this to a 1.9td, beware any reference to pipe sizes mentioned on here, the turbo outlet is 36mm and the other pipe is 45mm which matches the l200 intercooler.

for everyone else with the 2.5 I foud a place that supplies 55mm to 45mm reducers, Leyland hose and silicone.

 

DO you need to get a remap? Or will just fitting the intercooler give benefits?

 

I know this is an old thread, but it has the best pictures! Can anyone tell me how the long nose scoop gets fresh air to pass over the intercooler with this setup? I've taken the bonnet liner down, and I just can't imagine how any airflow actually gets to the intercooler this way. Trying to finish up my BHW TDI swap and it would be loads easier to not have a front mounted intercooler. I'm not making tons of power (nor do I want to), so a top mount should do fine for me.

Thanks!

 

If you look along the front edge of the bonnet the intake is there, just in-front of the rubber seal strip. Air is then ducted down into the cooler. The motion of the van creates a low-pressure area under the back of the engine compartment - thus drawing the warm air out (like a chimney).

 

Have you got the plastic scoop? Part number 701-145-843. It just clips in.