First, what I started with. A standard 4d56t engine bay.
And the standard intercooler from off a Pajero with the same engine.
Also needed the intake manifold from the intercooled engine as the intake positions are different.
You'll notice the intake position is verticle on the intercooled version where the non-intercooled is horizontal. There is however a EGR fitting on the intercooled manifold which needs to be blocked up. Easy job just cut the shape from 3mm mild steel and bolted on.
Non-inercooled manifold pic
Checked intercooler for fit in the engine bay.
Too much angle to fit on the firewall - needs to be bent to a right angle.
Not long enough to fit on the front support panel.
Cut the frame and added some rod inside the tubing for braceing and then added some larger tubing over the top for extra strength and length.
Also bent the firewall end to shape.
Intercooler ready to trial fit.
Needed to make up a couple of bracket to mount the intercooler to the front support panel.
Used 8mm rivnuts in the firewall and front support panel so the frame could be bolted up and look factory.
Removed the std manifold and fitted the intercooled manifold.
Bolted on the intercooler and fitted the piping.
Finished engine bay.
Then to cut out the bonnet, I masked off the area and using my eye-ometer, marked where the hole needed to be.
The drilled the 4 corners and cut out using a hand nibbler.
Had to cut through some of the bonnet braces but not too much.
I already had fitted the bonnet scoop from off a Bighorn.
