Water/Air Intercooler

[2spicey]

Hi all... This is my first post on NPORA. I purhased a mint 95 TD27 auto in 2010. After disabling the exhaust gas recirculation, my next mod was to intercool it. I didn't want to use the normal top mount air/air hole in the bonnet afair. I like water/air systems as they have short pipe lengths to reduce lag and are not affected by all the rising heat at low speed. Additionally, water has 4 times the ability to absorb heat than air so a reasonably compact heat exchanger can cool 4x better than the same size air/air heat exchanger. I used a complete set up including i/c radiator and water pump from a Subaru Legacy GT. The radiator is a perfect fit behind the standard alloy bash plate... where it fits perfectly and is overlooked by most. I did the mod roughly 3 years ago now and at the time thought that other Terrano/Patrol owners might be interested, so took photos as I went along. I am intending to take the next step in my project, fitting EGT gauge and increase fueling and boost levels a bit. Removal of the two standard mufflers and substituing a straight pipe in their place. I am aiming for power increase of around 20% over current levels, or about the same as if I asked my wife to run behind and push it!

)Hope I figure out how to add pics)... see below! (and yes.. that is a 12g shell used to blank off to the aircleaner... good spotting!)

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20002_zpshkdxgg25.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20003_zpskxi3vwld.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20005_zpsxmtarxje.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20009_zpson1ap9un.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20011_zps08mjwunq.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20001a_zpsicrmxadg.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20001a%201_zpsz8ktu968.jpg

 

http://i1167.photobucket.com/albums/q635/2spicey1967/Oct12%20012_zpszkztgyhw.jpg

[Slartibartfast]

I only vaguely understand what you did but it looks like a clean install. I like the shotgun shell, reminds me of the pressure switch I built for my glovebox a while ago.

[2spicey]

I also discovered 308 cases with the ends cut off make great hose joiners in a pinch! Back to the intercooler and at this point I must apoligise for the photos above. Had a little trouble getting them to post and couldn't edit it after I discoverd my mistake so you get to look at Mt Ruapahu too, in my Photobucket... Basically the top heat exchanger is full of water, the electric pump pushes it through down to the radiator, which is quite large at exactly the same size as the inside of the alloy bash plate. Most of the time, running around town etc, you can leave the switch on the water pump off and the heat transfers through the water naturally. I only turn the pump on under sustained load, like climbing hills, towing etc when the boost is running at 11 lb constantly. The set up is more efficient at controlling heat from the turbo, the down side is that the lower radiator is somewhat clog-able if ya like diving into mud wallows.... for on road use its great.

 

P.S Re your '93...it's the first time that I have ever seen where 'rat damage' has saved someone a lot of money!

[Slartibartfast]

Ah, that makes sense. How's the performance with the cooler running?

 

And yeah, I owe a lot to that rat LOL. Wish he'd found somewhere else to die, though...

[2spicey]

Around town there is no difference really, but under sustaind load, ie climbing big hills where you can be going up for 20/30min it used to really die off. With the intercooler it holds up a lot better. The diesel tech I work with wouldn't increase fueling and boost preasure until the intercooler was fitted. My Terrano has travelled 105ks so that's around 67miles I guess. I didn't want to damage a good car with lot's of life left in it. I had the factory mufflers off her last week and took it for a squirt around the block and was supprised how quiet it was. Turbo spool up was a lot quicker and the turbine whistle was more noticale then the exhaust note, so with a straight bit of pipe replacing the mufflers and the exhaust exiting the back (rather than under the passangers seat) it should be family friendly sound level wise.