Full width 200tdi intercooler

AlbertDefender90 · May 14, 2015

Hi all,

I'm looking at fitting a full width intercooler to my 200 before I put the body back on. What are my best options keeping price and modifications to a minimum? I've seen the allard and allisport ones but they are a little out of my price range

Thanks

Albert

3.5 efi · May 14, 2015

You can fit a standard td5 one quite easily if you centre the radiator in the mount. Cheap enough to pick up and just a bit of plumbing.

AlbertDefender90 · May 14, 2015

3.5 efi said:
You can fit a standard td5 one quite easily if you centre the radiator in the mount. Cheap enough to pick up and just a bit of plumbing.

How much of an improvement is a td5 one compared with some of the performance ones and over standard?

3.5 efi · May 14, 2015

Hard to quantify but it's about twice the size of standard.

jonnygurkha · May 14, 2015

Being new to all this what is the advantage of having a full width or enhanced intercooler and is it a fairly easy job to do on a 200tdi? Cheers!

AlbertDefender90 · May 14, 2015

Better cooling and airflow with a bigger intercooler I.e more power, as for how easy that's part of what I'm asking with different options

crowmann · May 15, 2015

300bhp/ton · May 15, 2015

jonnygurkha said:
Being new to all this what is the advantage of having a full width or enhanced intercooler and is it a fairly easy job to do on a 200tdi? Cheers!

A bigger intercooler on it's own won't really net much. The reason you need it is, as you compress air (via the turbo), you get heat as a by-product. But higher intake air temps aren't good for power. So you want to cool the air after it's compressed.

Early turbo engines didn't bother with an intercooler at all, but usually ran low boost. Such as the 2.5TD. The Tdi being intercooled is a good thing, but the stock intercooler is quite small.

If you want to tweak the injector pump for more fuel and tweak the turbo for more boost, then a bigger intercooler will allow a more aggressive tune and get the intake temps lower.

Barbados · May 15, 2015

Crowman,

That set up looks really good. Guessing you got that IC on ebay, I used to bay many of them for a supplier while I had my performance in Canada.

They are well built and fairly cheap, most not costing over USD 150. Never had any leaks or cracking. Hope you are running a puller fan, the ones I use are Spal 16" extracting low profile with straight blades.

IC plumbing looks good too.

lynall · May 15, 2015

I dont think I have ever seen an intercooler mounted behind the engine rad before.

Barbados · May 16, 2015

lynall said:
I dont think I have ever seen an intercooler mounted behind the engine rad before.

And you have not seen one behind the rad.....look again.

lynall · May 16, 2015

Oh yeh I defo need glasses!

AlbertDefender90 · May 16, 2015

crowmann said:

How much modding did that setup take to fit? Also do you have any links to where you got the intercooler from? [emoji4]

Thanks

Albert

AlbertDefender90 · May 17, 2015

Does anyone know the overall width of an rs500 intercooler minus the brackets? I'd like to try and fit one in the rad housing like crowman but I don't know how wide it is

Barbados · May 17, 2015

There are some good intercooler supplies on ebay. Simply measure the space in the landy and then go shopping. All the ebay IC suppliers lists the various sizes online.

You can get the IC and even a different rad like the one illustrated on this thread, that setup is great inclusive of the electric fan.

Since I am now in the tropics, I will go with a lower temp thermostat, a thermo switch rated with manual over ride for the fan and required warning lights.

I am about to go grab all my gauges which have programmable warning lights and stored peak values.

crowmann · May 17, 2015

The one I fitted (above pics) is the very biggest you can fit in the front IMV.

It made no discernible difference to performance btw, neither faster or slower.

crowmann · May 17, 2015

AlbertDefender90 said:
How much modding did that setup take to fit? Also do you have any links to where you got the intercooler from? [emoji4]

Thanks

Albert

Modding was essentially the electric fan and then hang the water rad off the old rad frame.

The pictures pretty much tell the tale. The IC was off the bay for around £90 IIRC - it was 6-7 years ago.

The silicone hoses added at least another £60 and the jubilee clips etc probably another £25 so the IC part came to sub £200 and was a 'nice' job to complete.

I then moved the wastegate feed to the inlet manifold, water injected it, fitted a boost valve and turned the pump up a few notches.

Goes well now. MPG 27 on 95% veg oil!

AlbertDefender90 · May 17, 2015

crowmann said:
Modding was essentially the electric fan and then hang the water rad off the old rad frame.

The pictures pretty much tell the tale. The IC was off the bay for around £90 IIRC - it was 6-7 years ago.

The silicone hoses added at least another £60 and the jubilee clips etc probably another £25 so the IC part came to sub £200 and was a 'nice' job to complete.

I then moved the wastegate feed to the inlet manifold, water injected it, fitted a boost valve and turned the pump up a few notches.

Goes well now. MPG 27 on 95% veg oil!

Thanks, what are the dimensions of the core? I could do with knowing to make sure it fits cos most of the eBay ones don't mention external dimensions. Also it would be nice to do a volume comparison with others I've looked at.

Full width 200tdi intercooler

AlbertDefender90

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3.5 efi

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