D3savage · Aug 19, 2013

Hi just thought i would report back - have just fitted large intercooler to TD4 :violent:....... 300x600x75mm ..... this was a very tight fit. Kept driverside feed position but had to redrill passenger side just under headlight.

Was it wiorth it ...I think so... some surprising effects were noticed...
1) Smoothness ... engine much smoother from 1100rpm to 1700ish
2) I can dirve quite happily on the flat in fifth at 32mph ..... it feels very
tractable and flexible)
3) Car feels livlier.... but not by a huge ammount (I think this will improve
with time as ecu learns new airflows)
4) Very keen to rev it will rort up 4500 easliy with no sign of holding back
I dont like doing this.....but had to test it.
5) Does not appear to be any serious turbo lag

Thats it so far, I am expecting a mild improvement in economy.... time will tell.....I used to get around 43mpg hoping this will go to 45..........

Synergy, K&N, egr bypass, inlet duct elbow removed, decat, large intercooler.

SES88 · Aug 19, 2013

This is what i want to do with mine, where'd you get it from? Allisport?

Which inlet duct elbow have you removed? The one between the wheelarch and the filter housing?

Wish i got 43mpg

cmmercer · Aug 19, 2013

43 sounds pretty epic! Got an EGR to fit but waiting to do it all when I also do oil change next week! wish I could get even close to 40+mpg

D3savage · Aug 20, 2013

Hi SES88,
The elbow I am refering to is the convoluted pipe leading to the EGR ..... it is all plastic
with a really nasty restriction just befor the EGR. It involves some carving..... but is easy
to do and really helps torque. Also the really crap inlet from wheel arch is very restrictive. If you want will post some picks for you.

Currently I have done 475 miles on a tank..... and I still have the last sector to go....
I estimate I can reach 500 on a tank.

I also run with high tyre pressures ..... as my Hankooks have very soft side walls
36 psi.

D3savage · Aug 20, 2013

What is super critical - is the engine thremostat.... my mpg went from 36mpg
to low 40's simply by changing a knackered thermostat. The high pressures in tyres help giving approx 2 mpg more.....Hankooks are wearing brilliantly have done 30k on then and still 6mm tread left!!!

Synergy is on max and VCU is quite new. I also use molyslip in the transfer box.

SES88 · Aug 20, 2013

Yeah some pics would be great if you can do please

I've swapped all my hoses for silicone and got rid of the EGR for an Allisport job.
Did your K&N make much difference? Been considering going for the Pipercross equivalent

I'm running big AT's which won't help like

RealBeale · Aug 20, 2013

Fitted an Allisport intercooler and silicone hoses about 18 months ago.It dwarfs the original.Made a massive difference.But that's been lost at the moment as I'm running on 205/80/16 MT's. Also I'm running a Synergy 2, but my MAF sensor is on it's way out. So I have to run with both switches on to compensate for the dodgy MAF because if I switch it off I struggle to pick up any speed at all and pulling out at junctions takes an age. 0 - 40 mph takes at least a mile !
With my 215/65/16 Grabber A/T's fitted it goes like stink when the Synergy is switched on, including MAF compensater. I have a brand new Bosch MAF ready to fit. I'll see what that does when the time comes. I'll try to post a pick of the intercooler being fitted too.I know I got a pic somewhere.

D3savage · Aug 20, 2013

Hi Ses88,
Yes fitted K&N .... but at the same time disconnected the air duct to the underwing intake.... and put on a large ram pipe ........ the overall effect was very noticeable - smoother and improved torque and reduced lag - mpg improved a little so it is win win.
Be careful though, with the intake into wing mod I think helps when wading through water....diesels and water are a disaster - so if you are not doing any serious wading it will be fine.

D3savage · Aug 20, 2013

Forgot to mention I use 2 stroke in TD4 this also helps mpg ......... I accidently put nearly 500ml in - the effect was intresting even smoother and improved tractability.
Diesel fuel today is ultra low sulpher ....... which used to provide allot of lubrication.....
the 2 stroke seems to help replace this and gives a nice smooth idle... i recommend 250ml per tank - only use std low ash 2 stroke either red or green ..... dont use synthetic.
Cheers

SES88 · Aug 20, 2013

Yeh i'll end up doing some wading so planning to keep the standard routing as i'll be designing a snorkel for it someday, replacing the woven hose may be a good shout though , i'll look at it.
I put some 2 stroke in when i filled up 2 weeks ago, bought halfrauds garden machinery 2 stroke, low ash mineral oil, red in colour, put way too much in though, about 1/3 of the bottle, by accident, was a bit smokey for the first couple of cold starts after, but its settled down now, i'll see how it goes over the next couple of full tanks and see if it improves.
Just changed crankcase breather this afternoon so see if that helps too.

D3savage · Aug 23, 2013

Hi SES88,
The air intake into the wheel arch is a real source of restriction ..... removing this and fitting a ram pipe gives noticable improvements to torque and bhp and smoothness.
I think..... a proper wading snorkle is a better bet ........

D3savage · Oct 4, 2013

Results after some serious miles:-
Better MPG ........ I estimate up to 10% - however performance is so good and addictive .... MPG has remained the same..... but acceleration and overal performance
is great ..... I am up into a higher gear some 20% earlier.

One example..... went to Cornwall ..... normally do about 42mpg averaging 65-70mph....
did this recently cruised at constant 75mph with the odd blast to 85.... result
42mpg..... The large intercooler seems to have made the engine breath far more easily
the car just gravitates and is happy at 75.

Haldon hill ..... near Exeter ..... matained 75 in 5th at only 1/3 throttle with a passenger. Before it was at least 2/3rds ..... and that was without passengers.

Interestingly I recon the std intercooler is ok for dissapating heat ..... it just seems to have really poor flow.

Hope you find it interesting......my next project will be to up the boost by 4psi

hd3 · Oct 4, 2013

Hope you find it interesting

certainly did

when i bought mine .. first thought for a mod. was an uprated intercooler
then had second thoughts 'n spent dosh on other bits for it ..
good to see a write up on the difference it makes ..
( was curious regarding mpg )

best o luck with the boost effort ..

RealBeale · Oct 5, 2013

Knew I had a pic of mine somewhere.

Skynet · Oct 5, 2013

SES88 Don't go wading to a level that requires a snorkel in a freelander! They float rather than sink due to a lack of holes, rusted or otherwise, so if you try you may end up downstream under a bridge!!!

D3savage · Oct 15, 2013

Update :- Large intercooler is awsome ...... to put the difference into perspective
it is almost equivalent to adding a synergy on max (say 70%) ..... + the car feels so much smoother and flexible...... I can comfortably drive at just over 30mph on the flat in 5th ..... no judders or vibration.

MPG:- Hard this I just keep using the extra power!!! But mpg is unchanged ..... I'm sure if I pootled around I would see at least a 5% improvement.

I have now ordered a Ron box to increase boost by 5psi ......... this should push power to around 165bhp with 260-270 ftlb of torque!!!

Will report back.

The aim of the above is not to create a hot hatch killer ..... road burner .... but a really flexible and economical car ........ I am aiming for my target of 45mpg .... currently
mixed commute is around 40-42mpg. Will keep you posted and take some picks.

D3savage · Dec 9, 2013

Updated:-
Have just fitted Rons Digibooster ....... to compliment the intercooler. This increases the boost from around 15psi to around 19psi. So fitted this as well as Rons recmended ZX1 friction reducer. Result.......yes tangeble, throttle response is better and there is deffinately a torque increase - as well as bhp. The effect was definately not as large as the intercooler I rate that as around 15% - this booster gives you around 7%.

When driving - you definately use less throttle ...... my synergy is maxed out on all settings ..... orginally produced some smoke on hard acceloration ..... this reduced with the intercooler and was further reduced with digibooster. Digibooster seems to make a difference from 1600rpm with the max effect at around 3000rpm.

The result is, this old freelander that has covered nearly 150k sails along - I have one test hill....orginally I had a 5 series 177bhp with 254lbf ..... this would do just over seventy up the test hill. My freelander now scrabbles to 65 mph just ........ so I recon she is producing around 165 bhp and around 260lbf........ not bad.

Mpg I am regularly getting 42mpg and have had just under 45mpg. I have just got her through the dreaded mot - she passed .... with a notification re a weak handbrake - not bad for a highly modded de-cat landy!!!

My next mod is the pierburg maf ......... will keep you posted.

matacaibo · Dec 9, 2013

RealBeale said:
Knew I had a pic of mine somewhere.

I think the winch bracket is a non starter with that monster installed

Does your aircon still work

RealBeale · Dec 9, 2013

matacaibo said:
I think the winch bracket is a non starter with that monster installed
Does your aircon still work

Not any more, but not because of the intercooler . The compressor started getting noisy and as I never used it anyway I decided to cut the belt.

D3savage · Dec 9, 2013

Hi I have had aircon working ........ but air con rad leaking.....this is on a never ending list.....to do. I can throughly recomend the large intercoolerand digibooster combo...

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