to intercool or not

Intercooler (e.g. Denco Diesel) will decrease intake air temperature and as a result you should see more efficient burn (slight increase in power). Increasing boost is not depending on an intercooler. Increasing boost is only relevant when the additional air actually finds something to burn. Increased boost is typical for power tunes (chips etc) and actually lowers EGR. Some power chips or programmers increase fuel flow but not boost and as a result some unburnt fuel will make it out the exhaust (smoke). In such situation increased boost will actually increase power and efficiency and reduce EGR. In the situation when you have a standard tune only a slight increase in boost might actually show an effect. The intercooler is not essential in my opinion although it is helping the engine and probably will increase engine life. By how much ? I would not know ... any modification which will lower EGR does help the engine. Just depends how you drive. You do not "need" an intercooler.
have fun
gmd

Hi Brad,
Go see the guys down Armadale 4wd if you're in wa (they seem to know the 100 series pretty well). If your'e gonna do the deal go the turbo, big inter-cooler, 3 inch exhaust and if you still got money in the bank bung the Dtronic chip in. That will drag the camper out of a bog if you need.

Cheers, Glenn

go hard or go home

bandk,
I am currently going through the same process i.e fitting a Denco to my 98 100 series. I have done the research and, for me, I have decided to go with the intercooler and as stated in this thread the exhaust system also. I do not have the stats at hand but the intercooler produces quite a bit more grunt due to the cooler more dense air. My other reason for going with the intercooler is because of running in extreem temperatures. For me, I figure, if I happen to run into some high daytime temps whilst bashing through a track, the reduced induction temps will only help a hard working engine. I don't normally plan to travel at the hottest time of the year but with the weather the way it is at the moment........who can tell.

Well worth the extra bucks.......for me anyway.

Toytruck

Hi Brad
We add a intercooler to our 4.2td nissan .Its been a great investment.We tow a 20 ft caravan and the diffence is incredable. More power and more kms to the L.Costed us $2000 fitted. Boost is now set at up to !5 from 8pound.
Spudnit