Page 1 of 1

Fitting Intercooler to 4d56t L200

Posted: Sat Jan 01, 2011 2:46 pm
by mudbugga
Well finally got round to fitting the intercooler, so I thought I'd write a little of what I did and put in a few pics as well.

First, what I started with. A standard 4d56t engine bay.
Image

And the standard intercooler from off a Pajero with the same engine.
Image

Also needed the intake manifold from the intercooled engine as the intake positions are different.
Image

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
Image

Checked intercooler for fit in the engine bay.
Too much angle to fit on the firewall - needs to be bent to a right angle.
Image
Image
Not long enough to fit on the front support panel.
Image

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.
Image

Also bent the firewall end to shape.
Image

Intercooler ready to trial fit.
Image

Image

Needed to make up a couple of bracket to mount the intercooler to the front support panel.
Image

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.
Image

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.

Re: Fitting Intercooler to 4d56t L200

Posted: Sun Jan 02, 2011 4:33 pm
by 44jetboat
nice you should be stoked with that.
would be interesting to see how much it lowers the intake charge.

i did something simlar with my 2.8 but moved the intercooler to infront of the raditor. trying to keep charge temp down when bogged in a mud hole or towing jetboat up hills. figured that would be cooler than heat soaking ontop of the engine.

Re: Fitting Intercooler to 4d56t L200

Posted: Sun Jan 02, 2011 9:39 pm
by mudbugga
Cheers.
Just got a few things to tidy up on it, like the bad cutting job on the bonnet, but that's for another day. :lol:

Yeah thought of putting the ic in front, but as there is sweet f-a room in front of the rad - on top it went.
Got the fan to wire up next and connect the water sprayer :wink:

Re: Fitting Intercooler to 4d56t L200

Posted: Wed Jan 05, 2011 7:06 pm
by dave gone jeepy
Thats really nice work you made it look easy