TD5 Intercooler into 200 tdi upgrade, i've made a start.....

[ne jones]

:D  After placing a wanted add for a Td5 intercooler I got to buy one from Hightower which was delivered yesterday.

This afternoon I got to take a look at what was actually involved in fitting it into the front of the 200 tdi Discovery.

After removing the grill and headlight surrounds I offered the 'new' ic to the front of the car and from this was able to determine how best to proceed with the fitting, it was obvious it wasn't going to be as straight forward as  first thought.

The front panel to which the bonnet closes is supported by 2 braces going from the bonnet catch diagonally to the bottom of the small panel where the horns are fitted. I unbolted both of these bars and removed them.

Next after offering up the ic again I decided that the right hand horn had to be removed completely as did most of the metal the horn bolts to. Out came the grinder, I think picture 0209 shows what I used it for  :D

The right side had to be cut away as 0211 pictures to clear the inlet on the ic.



On the left hand side the horn was reversed and only a small amount of trimming was required.

There is now sufficient room for the 'new' ic and when the standard ic is removed i'll be routing the pipework through the vacated area.

Now a plea for help as i dont own a welder and need some brackets fabricating. Is there anyone reasonably close to me that would be prepared to help me with this part of the upgrade please?

Gotta get me some silicone hoses now and sone straight pipe so that the plumbing can start.

If you can help us out then please let me know.

[Dr Neil]

keep the pictures coming Nathan,i've got my intercooler now but haven't got time to start on it yet.I've got access to a welder but i'm a bit far away.
Good look mate

Neil....

[ne jones]

Neil it all happened rather quickly.

Went to my brother in laws to weld up the brackets to moount the i.c and to have a mooch at the pieces of stainless tube he had in his garage.

Firstly I got the 2 90 degree silicone elbows and put them on the new i.c and offered it up infront of the radiator. To keep the ic as far back as possible i cut approx 1.5 inches off each elbow @ the ic joint. I also took the same amount off the other end of the elbow for the inlet side.

On the front chassis legs right where the bumper mounts to the chassis we measured and made some 80mm longx10.5mm internal diameter tubing for locating the 2 lugs on the td5 i.c.

I had bought some 90 degree steel brackets for 60p each and these were cut down and welded to the underside of the front panel where the bonnet catch is, the ic bolts to these brackets.

The front locating lugs on the ic were cut off too.

We removed existing i.c and cut down its plastic cover to give access into the engine bay down the side of the rad.

A piece of stainless comes from the outlet side of the ic diagonally across the front of the radiator and bends into the engine bay and uses the stock top ic hose.

The inlet side uses the stock pipework from the turbo going into a u bend then into the silicone elbow on the ic.

Finally the front grill required very minor trimming of its inside to all ow it to fit.

I'll take some pics of the job and post them later today.

All in it took us about 3.5 hours + the cutting I did in the previous installment.

[ne jones]

Some pics

1st one inlet from Turbo

2nd one is outlet to inlet manifold

3rd one is obvious.

[ne jones]

3 more

1st one shows original pipework from turbo

2nd one shows original pipework joined not to original intercooler but to the bend which goes to the silicone tube on the ic inlet

3rd one shows use of original hose to the inlet manifold, the ic outlet is connected to this pipe by a stainless pipe with bend around rad and silicone elbow on the ic.

[barmiebrumie]

Nathan, is there any change in peformance  :?: ,


Thanks

[ne jones]

There doesn't appear to be, but i was told only to expect about 3-5 bhp from the ic change.
The real gains come from adjusting the fuelling and boost which i'd already done.
Does anyone know what would be a maximum safe boost pressure to run with this ic?
Currently running @ 14 psi but have heard 18 psi is ok?
Is it?

[Dr Neil]

great pics Nathan, thanks!!

i noticed you didn't have to remove the fan cowling or move the radiator which was the two things i was concerned about.

I will have to start getting a few bits sorted and take the plunge!!

I noticed you asked about the boost. I have been reliably informed you can wind it up to 1Bar (.7 standard) or if your really brave you can open it up all the way as it will only boost 1.4 bar, though i wouldn't do it myself.

If you want a bit of extra oomph you could move the pick up point for the pipe onto the turbo actuator.Right here goes

1. disconnect the pipe that goes from the top of the fuel pump to the turbo actuator, then remove the Tpiece that goes into the turbo.
2.obtain a short bolt and copper washer to blank off the hole you have just left.
3.Remove the bolt that goes into the top side of the inlet manifold about half way along (just above the rocker cover).Get another bolt of the same thread and drill a hole down the centre of the thread and then from the side into the centre hole(alternatively you could try and buy one).Then obtain a banjo union to fit the bolt and two copper washers,and fit it into the manifold.
4.Obtain a T piece of the same diameter and some rubber hose,connect a short piece of hose to the Tpiece and join it to the banjo and secure with clips.Then from one of the other outlets of the Tpiece connect another piece of hose and join it to the origional pipe that comes from the top of the fuel pump and secure with clips.
5. You should now have one outlet of the Tpiece left.From this you need another short piece of hose connected to it.You then need some metal pipe to route through the exhaust manifold up to the Tpiece and connect it to the hose.At the turbo actuator use the existing short rubber hose and connect to the metal pipe.

You should now all be connected up (providing i haven't forgotten anything).The next step is to start up the engine and go for a spin!!!
And i can tell you it Does make a difference!! :D .

Whilst i have done this to my vehicle i cannot accept any responsibility if it goes bang or causes any damage(though i have been told it will be o.k)

I will take some pics and put them in my gallery when i get chance as it may seem clearer than all those words.

hope this helps

Nei....

[ne jones]

Thanks Neil.

I used the car for getting some furniture from Ikea today and commented to the wife that it didn't seem to have 'much' pull. She also asked what that noise was? Since i mostly to music I hadn't heard any noise.

Went out tonight with no weight in the car other than my 19 1/2 stone and the car was definitely not pulling aswell as before the conversion. The boost was about 2 psi lower aswell.

I tightened some jubilee clips, got more torque on them with a large screwdriver and checked the pipes for splits etc.

What I found was the weld on the u-bend is blowing, my thoughts are that this is responsible for the loss in performance and the 'noise' SWMBO heard too.

I have got two 3" silicone connectors off ebay and when they arrive i'll replace the joint i know is blowing and if necessary the other weld too.

Probably be the weekend before I know whats what but i'll post the results on here.

Doing a run down to Newport Gwent on Sunday, then Monday up to Lampeter so I gotta cure it before then.

[Dr Neil]

Have you tried re adjusting the fuel pump now that you have fitted the intercooler as now you have a bigger one you should be able to allow more fuel in without too much smoke, that is why when you have a performance intercooler fitted they adjust the pump afterwards otherwise you are cooling the same amount of fuel quicker instead of more fuel(if you know what i mean)..

hope this helps

Neil......

[ne jones]

Neil gonna wait until blowing weld is replaced before doing anymore adjustments. Also dont want to turn up the fuelling at the expense of mpg or very high egt. I havent got an egt gauge and cant really justify the expense of one to be honest, so id rather play it safe.