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  #81  
Old February 12th, 2009, 10:24 AM
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Quote:
Originally Posted by Maryland 110
Already have upped the fuel and boost a bit. The highest I have gotten it is 1000 degrees.
Up it more. I can hit 1200 no problem. 1000 is way below trouble area.
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  #82  
Old February 12th, 2009, 11:36 AM
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Headed that way- need a boost gauge first
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  #83  
Old February 15th, 2009, 04:16 PM
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Anyone, dimensions on the hoses for the oversize intercoolers?
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  #84  
Old February 15th, 2009, 06:41 PM
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I re-used the stock elbows
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  #85  
Old February 15th, 2009, 11:23 PM
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Quote:
Originally Posted by JSQ
Anyone, dimensions on the hoses for the oversize intercoolers?
Stock size. I know the new intercooler hoses are all pretty and whatnot, but they are not worth the money. They do nothing but add dressup to the motor. If you still want them, go to Kartech in corona and rummage through the silicone hose bin. They have more reasonable deals. I think allard is something like $100 for the hoses. Total ripoff.
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  #86  
Old February 16th, 2009, 02:41 PM
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Quote:
Originally Posted by Buckon37s
Stock size. I know the new intercooler hoses are all pretty and whatnot, but they are not worth the money. They do nothing but add dressup to the motor. If you still want them, go to Kartech in corona and rummage through the silicone hose bin. They have more reasonable deals. I think allard is something like $100 for the hoses. Total ripoff.
Word.
I have no hoses so I might as well get the slick ones. I'll probably use this www.siliconehose.com joint and get a set in black so they're not too El Pimp.
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  #87  
Old May 14th, 2009, 12:02 PM
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So anyone install one of these? Pictures? Review?
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  #88  
Old May 14th, 2009, 01:22 PM
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Might get around to messing with my Allard today, but its on a Disco
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  #89  
Old May 14th, 2009, 04:11 PM
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I might give it a go over the weekend.
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  #90  
Old May 14th, 2009, 05:21 PM
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Not the Allard. I'm sure that is fine.

I'm talking about the $150 eBay special. Would like to know how the sizing works out and the performance. It is less than a 1/3 the cost of any other option, so if it is good, I'm all for it.
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  #91  
Old July 12th, 2009, 08:00 PM
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Okay months later I got some time and installed said intercooler.

WHAT A PITA!!!! Not so much but the usual stuff gets in the way.
Once the IC is in place it's nearly impossible to tighter the bolts for the hood latch support. trimming was done to the breakfast to clear the cooler and the fan shroud. I still need to pick up a 45 degree 2" turbo hose for the lower connection.

I built a bracket that used the tabs that the hood latch supports went to and then came down from the hood latch support for the upper mounting.

No can fit the safety catch for the bonnet so hood pins are in my future..

As usual I suck at pics. So no documentation..

Performance results will come soon...
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  #92  
Old July 12th, 2009, 11:02 PM
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I don't know if it is the same on the 300tdi but on my 200tdi, with stock injection pump settings and this intercooler, I was hitting 800F at 65mph and 925 tops on strong climbs at highway speeds in fourth gear. Now I can't say if this allot lower than with a stock intercooler as I didnot have an EGT prior the intercooler install.

Hope it helps and yes it is allot of fidling to get that in and still wandering if it was all worth it. At this moment I have played with pumps setting and will be putting more fuel in but before I do that I have to install the boost meter.

Hope this hepls.

Pat
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  #93  
Old July 13th, 2009, 08:32 AM
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What I did was to make two plates that came from the inside bottom plate of the radiator/intercooler box. These had holes and gromets for the pins on the bottom of the intercooler. For the top/side mounts I used strap steel about an inch wide and attached/bolted them to the intercooler and then radiused/curved them back to the outside edges of the radiator box and welded them. This way the radiator and intercooler still remove from the truck as a unit. The weight still rests on the rubber mounts on the top of the frame rails. Its plenty ridgid and has been problem free for six months. I did have to trim the stock fan shroud for the intercooler inlet and outlet hoses and I also removed the cross bar braces that strengthen the hood latch panel for clearance for the intercooler. I have an early truck so it had the neat manual "reach through the grill" hood latch and that still works fine. The biggest issue I had was the repeated in and out of the truck with the very heavy radiator/intercooler box while we mocked it up. Thanks again to Charles Galpin for helping me with that project. If memory serves we started @ 1 in the afternoon and finished around 9pm on a Sunday night. One of the things that needed correcting was mounting the intercooler low enough to clear the hood latch mechanism.
From a performance standpoint I now have trouble getting above 1050 on the egt. My fueling has been turned up signifigantly. I have an a/c system to install and will probably move the pins on the bottom of the radiator frame/box in order to move the netire thing back towards the engine fan. There is about a foot between the raditor and fan so moving the entire box back about 2 inches to make room for an a/c condensor and fan should be no problem.
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  #94  
Old July 13th, 2009, 09:54 AM
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Quote:
Originally Posted by Maryland 110
What I did was to make two plates that came from the inside bottom plate of the radiator/intercooler box. These had holes and gromets for the pins on the bottom of the intercooler. For the top/side mounts I used strap steel about an inch wide and attached/bolted them to the intercooler and then radiused/curved them back to the outside edges of the radiator box and welded them. This way the radiator and intercooler still remove from the truck as a unit. The weight still rests on the rubber mounts on the top of the frame rails. Its plenty ridgid and has been problem free for six months. I did have to trim the stock fan shroud for the intercooler inlet and outlet hoses and I also removed the cross bar braces that strengthen the hood latch panel for clearance for the intercooler. I have an early truck so it had the neat manual "reach through the grill" hood latch and that still works fine. The biggest issue I had was the repeated in and out of the truck with the very heavy radiator/intercooler box while we mocked it up. Thanks again to Charles Galpin for helping me with that project. If memory serves we started @ 1 in the afternoon and finished around 9pm on a Sunday night. One of the things that needed correcting was mounting the intercooler low enough to clear the hood latch mechanism.
From a performance standpoint I now have trouble getting above 1050 on the egt. My fueling has been turned up signifigantly. I have an a/c system to install and will probably move the pins on the bottom of the radiator frame/box in order to move the netire thing back towards the engine fan. There is about a foot between the raditor and fan so moving the entire box back about 2 inches to make room for an a/c condensor and fan should be no problem.
Hey,

If you don't mind, can you take a picture of the engine location? I want to see why I have very little room between the rad and engine and most seem to have a lot. Thanks
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  #95  
Old July 13th, 2009, 10:02 AM
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Dave

you have a 300tdi/r380 combo, mounted more or less in the stock location though IIRC you told me you had to mount it an inch or so back because you kept the lt77 floors. the 200tdi uses the old lt77 boxes with the short bellhousing, and so it sits much further back from the radiator than the 300's.



Quote:
Originally Posted by Buckon37s
Hey,

If you don't mind, can you take a picture of the engine location? I want to see why I have very little room between the rad and engine and most seem to have a lot. Thanks
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  #96  
Old July 13th, 2009, 10:30 AM
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Quote:
Originally Posted by Ren Ching
Dave

you have a 300tdi/r380 combo, mounted more or less in the stock location though IIRC you told me you had to mount it an inch or so back because you kept the lt77 floors. the 200tdi uses the old lt77 boxes with the short bellhousing, and so it sits much further back from the radiator than the 300's.
thanks. I didn't see it was a 200. All that space would be nice!
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  #97  
Old July 30th, 2009, 06:41 PM
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I finished putting the ebay intercooler into my 110 for the re-power.

http://lh6.ggpht.com/_8AqLEYwCLgc/Sn...2/P1080457.JPG

I doubt my install details will be very helpful for anyone other than Dave or those with Ex-MOD trucks, but regardless, I had plenty of room to accommodate the larger intercooler. When positioning my powertrain I kept the mounts for the t-case and worked forward from there. With the short gearbox the engine had plenty of clearance in the front. I actually had to move the radiator back quite a bit to get the fan shroud over the fan.

http://lh6.ggpht.com/_8AqLEYwCLgc/Sg...0/DSC04031.JPG

I know most have tried to keep the intercooler and radiator boxed together as a single unit, but I decided I wanted to be able to remove either of them seperately. To that end I added a second set of mounts from a donor D-90 to the crossmember for the intercooler to sit on.

http://lh3.ggpht.com/_8AqLEYwCLgc/Sn...0/P1080476.JPG

And I welded a bar across the diagonal rad supports to bolt to the face of the intercooler.

http://lh4.ggpht.com/_8AqLEYwCLgc/Sn...2/P1080481.JPG

There's plenty of space for the radiator and intercooler as it sits.

http://lh3.ggpht.com/_8AqLEYwCLgc/Sn...2/P1080480.JPG

I had to trim the inlet to clear the steering box and switched to a 45 degree bend hose. I had a bead TIG-welded onto the inlet to prevent the hose from slipping.

http://lh3.ggpht.com/_8AqLEYwCLgc/Sn...0/P1080463.JPG

I'd say it was relatively straightforward, but I don't have any fans, A/C condenser, oil cooler, tranny cooler or any of that other stuff to deal with. Life is simple.

More pics on the thread I have going on the EE bbs.

Don't ask me how it works, I still haven't turned the key on this motor.
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  #98  
Old July 30th, 2009, 07:34 PM
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Thats one way to use the extra 2" you get when you put the transmission back in the LT 77 position. Hope you get to fire it up soon.
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  #99  
Old July 30th, 2009, 07:56 PM
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Hey Jack,

Your truck looks awesome. Thanks for doing that. Unfortunately, even though I moved my engine back 3.5in from stock, I used up all the space available by mounting my winch behind the grill. Can you tell me how tall the intercooler is? I only have 9in vertically to play with.

PS: I really like your radiator mount. Very nice and clean.
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  #100  
Old July 31st, 2009, 12:13 PM
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Thanks. We'll see what happens.

Quick question:
What is this line coming off the injector pump?

http://lh4.ggpht.com/_8AqLEYwCLgc/Sn...0/P1080471.JPG

Is it a breather?

It's not in any pictures in the shop manual and I can't find anything on the web.
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