Top Mount Intercooler Fit Up

[Jimmu]

Thanks for the responses. I will fit an inline fuse to it to be safe. To be honest I dont know what to tap it into to switch off with the ignition. I need a test light, to poke around with. I dont think I would leave it on though as it is bloody loud without the engine running.

It seems ok on water so far. I reckon it would take 3-5 minutes of constant use to empty the reservoir I have.

It definately helps. The core is cool to touch after 10 minutes of hard driving whereas before it was quite warm.

Automating the spray based on temperature would be the way to go.

Now for the Pyro meter.

Jimmy

[adam]

How is your economy now with the exhaust and intercooler and dyno tune?

[jeremp]

I LOVE IT!!! THat is exactly what I am planning with my Rodeo.

dieselrodeo.blogspot.com/

[quack]

hey Jimmu just fitted my topmount to my 2.8 mu, was quite easy but turning the turbo housing was a bit of a pain in the arse.

just wondering if you could post some pics on how you braced it. at the moment mines just held on by the hosing.

also some pics of the fan and water cooler would be good:)

any way thanks heaps on the detailed instrutions and pics on how to!

[Jimmu]

Sorry for the delay Adam. I totally missed your post until just now. The economy does not appear to have changed either way. Which has to be a good thing considering I tend to use the extra ponies just because it puts a smile on my face.

Good to hear Quack. I will snap some shots this week of the Fan and waterspray setup.

The bracing is not pretty, I bent up some galvanised brackets but I kept breaking the alumnium brackets I made.

Jimmy

[Jimmu]

Here is the Fan:



The Waterspray Reservoir:



The Spray Tip:



Switches and EGT head unit:



Jimmy

[quack]

wow that looks good! wots the EGT headunit do?

wouldnt the fan be better mounted under the intercooler sucking air though it?

were did you get you fan and water cooler setup? and is it wired with temo switchs or just manual?

fitted the scoop to the truck today, the cooler still stays quite warm tho but there is a good inpovement to the power

[Jimmu]

EGT = Exhaust Gas Temperature. It measures the heat the exhaust gasses are at to give a pre warning of overheating of the combustion chamber. Becuase I am running much higher boost and fuel the engine could get hot so this lets me keep an eye on it and know how long I can hold it flat without starting to do damage.

There is just enough room under the core to fit the fan but it would severely restrict the airflow past the core so I left it on top. I am going to fit a 12" thermo soon to get more airflow.

Fan from Ebay. Waterspray kit from Supercheap. It is a generic windscreen washer reservoir and pump and some garden mister attachments.

The water spray makes a huge difference to the core temperature.

Keep in mind that the intercooler by itself will do very little to improve power. But it does allow you to safely run much higher boost and fuel which will generate much more power.

Jimmy

[holden]

4. Rotating the Compressor Housing on the Turbo



There are some bolts holding brackets that clamp the housing to the body. These were loosened and in the case of the bolts holding the actuator bracket removed and refitted.

This was a pain in the arse as you can see by my questions in another thread. Thankfully Yarno who has already done it was there to keep me on track. I was about to pull the turbo off.



The nut in red circle was almost impossible to get to. I had to remove the warm up thingy and forceably rotate the bracket holding the waste gate acutator to get access to it.

When you rotate the housing do you move the waste gate mount along to the next bolt holes on the housing so it lines up

[dasnoboarder]

Yup, on your 4jb1 that's how it's done.

[holden]

4. Rotating the Compressor Housing on the Turbo



There are some bolts holding brackets that clamp the housing to the body. These were loosened and in the case of the bolts holding the actuator bracket removed and refitted.

This was a pain in the arse as you can see by my questions in another thread. Thankfully Yarno who has already done it was there to keep me on track. I was about to pull the turbo off.



The nut in red circle was almost impossible to get to. I had to remove the warm up thingy and forceably rotate the bracket holding the waste gate acutator to get access to it.

Can anyone PLZ tell me a detailed description of how to bolt the bottem bolts on the turbo housing after you rotate the turbo housing to fit a intercooler. Its harder then it looks.

kane

[Bruce]

Hi Holden, I have a new turbo to fit to the Wizard and I can see that it has to be turned one slot, so easy to do with the turbo removed, so may be that is the best way to go. Just make sure to check the nuts on the turbo to manifold etc after you have done a couple of hundred Ks.Let me know if it works thanks Bruce

[holden]

Aug 2, 2008 21:44:42 GMT 11 Bruce said:

Hi Holden, I have a new turbo to fit to the Wizard and I can see that it has to be turned one slot, so easy to do with the turbo removed, so may be that is the best way to go. Just make sure to check the nuts on the turbo to manifold etc after you have done a couple of hundred Ks.Let me know if it works thanks Bruce

I just got them in and did have to remove the turbo but was very hard.

[Jimmu]

I just fitted them back in with some skinned knuckles and an hour of profanities.

Jimmy

[kenny]

I Just went through the pain of rotationg the turbo today. A little trick I ended up doing to get the bottom bolts in was to cut a groove in them with a hacksaw and then use a screw driver to get them started and most of the way in. Only thing was that I dropped a bolt and it didn't fall right through and I can't find it. This would have to have been one of the most fiddly and frustrating things I have ever done!

[holden]

Here is the Fan:

Whats the best way to wire the intercooler fan as I have just hooked mine up to my thermo switch that my Radiator Fan is hooked up to. (92c water temp turn on). Or sould I wire it so it run as soon as I start the engine and stops when I trun the engine off?? (full time) Note: how it is hooked up now the 2 fans can run when engine is turned off till the radiator gets down to 82c.

kane

[geeves]

Idealy a separarate temp switch in the intake manifold that comes on at say 25 - 40c The intake temp is unrelated to water temp ie open road and the intake will be well cooled but slow stuff and it goes up and you get to use your fan

[holden]

Idealy a separarate temp switch in the intake manifold that comes on at say 25 - 40C Would be ideal but not at a ideal price and if I run it full time for free it will allways be supercold but might have to buy a new fan every 2years. ill try it like that and see how it goes. kane

[Yarno]

When I had a fan on my cooler I just hooked up a relay to the alternator so when the alternator was putting power out (engine running) the fan was running and when engine off it would stop.

[geeves]

Jaycars sell tiny electrical thermo switches for about 20 You will probably need to use a relay as well as I dont think they would handle fan current. Anouther way is to wire it to your 4wd light. On road its not often the fan will give much help as airflow above 50kph is enough but off road it will be a help most of the time