Intercooling - not worth it.

Submitted: Friday, Feb 27, 2009 at 14:45
ThreadID: 66345 Views:8514 Replies:13 FollowUps:5
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After researching ways to extract extra grunt from my 80 series Turbo Diesel Auto (24 valve) for towing purposes. I had a water to air Intercooler fitted by a company who are big advertisers in the back of, and highly recommended by, a leading monthly 4WD mag and A four day job turned into a four week disaster and finally the Intercooler has been removed.
On getting the vehicle back the first time with a bill for over $5000 (including valve clearance adjustment and reco injectors/seats etc.. I couldn't go faster than 85 km/h up the freeway! Towing a boat the next day I was down to 30km/h.
I kept returning the car to the installer first to have the engine work re-done then an intercooler radiator leak fixed, then the intercooler water pump fixed and each time they claimed increased power and torque even though 'seat of the pants' indicated no I repeat no increase in performance. The installers final figures off the Dyno exceeded the 100 series landcruiser and came close to the new 75 series V8!
An independent tuning specialist says in his opinion the heat exchanger is too small to have any worthwhile cooling effect on hot air out of the turbo. From my experience I would have to agree this intercooler and the installer are full of said hot air.
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Reply By: SPRINT-GTO - Friday, Feb 27, 2009 at 15:26

Friday, Feb 27, 2009 at 15:26
Suggest you trade the 80 in and get yourself a 1HD-FTE.
The $5000 could have been better spent??
Good Luck.
AnswerID: 351342

Reply By: Bob of KAOS - Friday, Feb 27, 2009 at 15:50

Friday, Feb 27, 2009 at 15:50
LPG injection worth a look? Or just a chip? Maybe extractors?


Or all 3 for just under $5000?
AnswerID: 351351

Follow Up By: Falco80 - Saturday, Feb 28, 2009 at 10:48

Saturday, Feb 28, 2009 at 10:48
KAOS you can't "chip" a mechanically injected 24 valve Toyota turbo-diesel, and you cannot fit extractors to a turbocharged vehicle. You can fit a tuned length exhaust manifold though, like the kids put on their 4 cylinder rice rockets, but on a 4.2TD it's not worth it.

Cheers,
Dan
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FollowupID: 619730

Reply By: Isuzumu - Friday, Feb 27, 2009 at 16:17

Friday, Feb 27, 2009 at 16:17
Firstly the intercooler will not by itself give big gains in power. Hopefully they explained this to you before they fitted it, the intercooler cools the air from the turbo to the engine allowing you then to tune, (add more fuel/air) most intercoolers give 5% t 8% by them selves.
I brought an air to water intercooler out of the States and fitted myself at a cost of around $750 put it on a dyno and turned up the fuel and boost, I already had a three inch mandrel exhaust, which give up to 15% on its own, after this we got another 15% odd, now goes like a shower of sh!!.
Sorry I think you have been lead astray, I would ask for all my money back.

Cheers Bruce
Cheers Bruce
D.Max and Jayco Outback

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AnswerID: 351357

Reply By: SPRINT-GTO - Friday, Feb 27, 2009 at 17:26

Friday, Feb 27, 2009 at 17:26
Yeah, if you cant upgrade to 1HD-FTE I would have thought do the 3" exhaust bit plus a chip-- Dtronic or DP whichever you prefer.
I have the Dtronic chip and 3" exhaust on my auto 1HD-FTE and it flies!!!
AnswerID: 351370

Follow Up By: SPRINT-GTO - Friday, Feb 27, 2009 at 17:29

Friday, Feb 27, 2009 at 17:29
Ralphc
Where are you located???
Go and have a yarn to Duncan at Macquarie 4WD.
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FollowupID: 619641

Follow Up By: Member - Shane D (QLD) - Friday, Feb 27, 2009 at 18:25

Friday, Feb 27, 2009 at 18:25
The 24 valve in the 80 series don't have computers.
Shane
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FollowupID: 619646

Reply By: Member - Shane D (QLD) - Friday, Feb 27, 2009 at 18:36

Friday, Feb 27, 2009 at 18:36
I owned (past tense) a turbo 80 (1HDT) which was pre 24 valve and it didn't need $5K spent on it to make it go.
Its easy to get on here and say what you should of done, should do next, but personnally I would get the thing tuned properly first and then see if it needs "modding".
My 80 only would do 165, only because it ran out of revs, still pulling hard at 160.
I wouldn't have a clue who to recommend to you(I don't even know where you are) but I would check out the basic's and get it right.
Shane
AnswerID: 351378

Reply By: ross - Friday, Feb 27, 2009 at 19:31

Friday, Feb 27, 2009 at 19:31
The title of this post is so misleading.

It should have read" Dont take your vehicle to carpet baggers" or "Study up on forced induction before you get ready to hand money over"
AnswerID: 351385

Reply By: Member - DOZER- Friday, Feb 27, 2009 at 20:29

Friday, Feb 27, 2009 at 20:29
Mate, ask the fools if they put the right injecters in it...the hdft injecter is different to the hdfte injecter although they bolt in....does it still go no good, or is it back to going ok.
Andrew
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AnswerID: 351405

Reply By: Truckster (Vic) - Friday, Feb 27, 2009 at 20:50

Friday, Feb 27, 2009 at 20:50
So who is this brilliant company? I havent wasted my money on 4wd magazines in 5 years. (THIS PROVES MY POINT AS TO WHY NOT BOTHER!!!)

Is it the one that cant be mentioned here or they will take legal action against EO owners? Sth of Sydney?

$5000??? WTF?

I gather you got a full refund for failing to deliver?
AnswerID: 351408

Reply By: rumpig - Friday, Feb 27, 2009 at 21:52

Friday, Feb 27, 2009 at 21:52
sounds like your installer isn't worth a pinch of sh..
maybe post up your location so that we can reccomend someone else for you to have a look at it.
AnswerID: 351418

Follow Up By: Rossco td105 - Friday, Feb 27, 2009 at 22:17

Friday, Feb 27, 2009 at 22:17
I second this sentiment...
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FollowupID: 619683

Reply By: Member - joc45 (WA) - Friday, Feb 27, 2009 at 23:04

Friday, Feb 27, 2009 at 23:04
"The installers final figures off the Dyno exceeded the 100 series landcruiser and came close to the new 75 series V8!"
And it wouldn't go more than 85km/h up the freeway?
I'd be inclined to doubt their results from the dyno!
AnswerID: 351432

Reply By: Member - Phil G (SA) - Friday, Feb 27, 2009 at 23:20

Friday, Feb 27, 2009 at 23:20
Are the following links of any use to you?
http://www.lcool.org/technical/80_series/intercooler.html
http://www.lcool.org/technical/80_series/1hdft_pump_adj.html
AnswerID: 351438

Reply By: Ralph C - Saturday, Feb 28, 2009 at 11:47

Saturday, Feb 28, 2009 at 11:47
Thanks for the many responses to my story of woe. Here are my responses to the suggestions received.
I live on the Central Coast of NSW. My 80 series has already had a 3" mandrel bent exhaust (Beaudesert) fitted. Best mod I ever made. You can't fit a chip to an 80 series they are mechanically not electronically injected. The company who fitted the intercooler was West End Diesel, Wetherill Park. I saw several unhappy customers come and go during the hours I spent there.
I only got the 90% of the cost of the intercooler back so far, 10% to come when they get it from Denco. No labour, no compensation for 1500 kilometres extra travel, no apology, nothing. In fact the said I was a nuisance coming back because they had so much other work booked in. They refused mediation through The Office of Fair Trading so it's off to the Tribunal next. I think they may have fitted the incorrect injectors the first time, the engine nows runs the same as it did before I took it in. The cost of the engine work came to $2000.00 and the intercooler $3000.00. The first time I went to collect it they kept me waiting 5.5 hours and the whole time the car was being revved hard on the dyno. When they took the intercooler off I asked them if they were going to re-dyno it. No they said It'll be fine. This means they might not have adjusted the fuel air mixture. This company say they do all Toyota warranty work so beware if your Toyota needs warranty work. They also claim to do the Aussie Army and State Transit. No wonder our buses don't run and heaven help our Guys in Afghanistan.
AnswerID: 351476

Follow Up By: awill4x4 - Saturday, Feb 28, 2009 at 12:44

Saturday, Feb 28, 2009 at 12:44
Ralph. Was the intercooler a "barrel" type water to air intercooler? and if so was it the smaller 4" (100mm) diameter version?
If it was, I firmly believe these 4" diameter coolers are way too small to do the job effectively, you simply can't flow enough air through them.
A simple test would be to test the boost pressure coming in and out of the intercooler, I'd be surprised if there wasn't a noticeable pressure drop at the cooler end of the intercooler.
Regards Andrew.
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FollowupID: 619748

Reply By: Ralph C - Saturday, Feb 28, 2009 at 22:22

Saturday, Feb 28, 2009 at 22:22
Hi Andrew, Yes it was the 100mm barrel type and Yes I have since had it confirmed by two independent tuning experts that this type and size of heat exchanger will not make diddly squat difference in this type of application. The intercooler has since been removed. One thing I forgot to mention in my original posting was the installer made up an intake manifold which left the heat exchanger floating in mid air above the engine supported only by the rubber hoses and the manifold. This of course would have failed in the first few hundred corrugations. Also the bonnet wouldn't close properly. The heat exchanger pressed it upwards.
AnswerID: 351568

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