Project Mud Catcher ( Front Mount Intercooler LN130 )

[JimmyT]

Front Mount Intercooler on my Surf

After having a search around on the internet I was not happy with the various Inter cooler Setups people have made for LN 130 Surfs. The top mount inter coolers didn't seem big enough and other front mount setups had very long ugly piping.

I decided i could do a better job.

I purchased a Misti Vr4 inter cooler, popular upgrade for a lot of models the boy racers love them as they flow well and are compact.

So far I Have 2x 2" U bends 1m of 2" pipe and half of a 2" donut.

Progress.

Inter cooler in poisition


Existing hole has been opened up slightly


Turbo side Piping tac welded


Turbo side Piping Test fitted



I still need to create a hole for the for the Intake side piping and make brackets for the bonnet latch support and to fix the inter cooler in position

I am also not sure how i will do the Air Filter/Snorkel Piping, I am considering using a larger diameter pipe and having it pressed into an ovel shape to allow enough clearance for everything to shut.

With the addition of a Pyro and Boost gauge I should be able to increase boost to 11 or 12 psi and have any fueling adjustments made.

[JimmyT]

I have been freezzing my ass off doing more cutting for the intake side piping



and this is how the complete "Kitt" looks



With a 2.5 to 2.0 reducer that will take care of the intake side

and 2x 2.0 90 deg silicone bends should tidy up the main piping nicely

[Lynx]

Well Done, not picking holes or anything, but, wont it be next to useless for 4x4, due to the low speeds??

Cheers Daniel

[JimmyT]

I'ts more for on road gains than for 4wd

but it should give a nice bit of extra puff up hills and for motorway driving ( daily vechicle )

if i can find some low profile fans i might fit them for more gains offroad

[chrome]

subaru wrx fans are shallow as and cheap as chips

[JimmyT]

Have done some more fitting and finishing.

Had to re do the Intake side piping, cut the hole for the intake side piping and checked that the battery and washer bottle still fit.

All going well I can have some brackets made and its finished after its welded.

Passenger side hole extended downwards with piping & hose all fully attached


Completed Intake Manifold Side Pipe


Washer bottle retains its original location, a simple bracket will fix this.

A rubber stopper against the AC pump body will stop the belt hitting the pipe with any movement from the engine.

( battery needs moved over as its pressing on the pipe I'm just a a bit lazy and wedged it right in there )

[JimmyT]

I know it has been a long time

But i have finally finished the inter cooler Piping off

The intake pipe is clearance to fit on a non body lifted 4wd.

and put it in service.

Power and fuel Economy are improved and it isn't even running more boost or had a diesel pump adjustment yet

pics of the finished setup.

[Landscaper]

How much better power and econ and were in the rev range or situation are you feeling the power increase ?

[JimmyT]

From a 10 days driving ( road miles ) it seems to do about another 20-30 km per 1/4 tank

which once you stack that all up is quite a nice increase.
I am still yet to do a proper mileage test on a full tank of gas.

No inter cooler got me a consistent 430 km per tank.

i can notice a bit of extra power from 80 kmh once the auto locks up in top. It used to die down quite a lot at 80kmh but now it accelerates to 100 kmh much much better

Note this is a 2.4 which is a fully run in fresh motor with de restricted exhaust and emissions control removed.

also if you nail the party pedal it seems to rev to 3500 a lot more freely than it used to, normally it would get to 3000rpm and take its time.

At the moment its only running factory boost, and once you take into account a pressure drop in the inter cooler its probably seeing slightly less boost than with no inter cooler

plan is to get the EGR gauge on it, crank up the boost and diesel pump until I can get some good power out of it.

the intercooler was mostly a way to keep temps down so i can go about adding more boost safely, being a brand new motor a Diesel specialist will be doing these adjustments.