Finally I got the intercooler in place.













Here is the link for more Pics of the intercooler.

Very clean looking work.
Brian

Installation looks nice. Have you noticed any change in performance since the addition of the intercooler? Any modifications to fueling etc.?

I have not done anything to the fuel adjustment yet. I have shorten the wastegate rod to increase boost. Perfommance is excelent I can go up hill in 4th gear without any prob. It seems like more power at about 2800rpm, I can go from 100km/h to 120km/h easily. There is plenty of power left, I hardly need to put the foot on the floor now. Worth of 5 hours work, very happy.

Yeah man that's sweet.
I have to ask the stupid question right away to show my ignorance. Did you pull the factory turbo and add the intercooled turbo? Your work is so clean I can't tell but it looks like you added the thing-a-ma-jig on the top and away you went. Where did you go to find out how to do this mod? Or, did I miss the whole thread and my bad?
Brian <img src="/forums/images/graemlins/baby.gif" alt="" />

That turbo comes with the engine, I only needed to modify the inlet fitting by 90 degree (it used to point backward to the firewall for the turbo fitting and now I have it pointing toward the intercooler).

The process quite straight forward:
1) Measure the inner section of the intercooler (only the core area)
2) Cut the hole on the bonnet with the area above ( find the right place in engine bay first to see if anything will be on the way first of course -:)
3) Close the bonnet then get the string to mark left+right cuts then front+back cuts so you have 2 marks on the guards and so on...
4) Open the bonnet use masking tape to join the marks and the small area enclosed by 4 lines in the middle is the bonnet scoop hole.
5) I used temporatory brackets to hold the intercooler up then adjusted the gap b/w the bonnet and the intercooler, I then left those brackets in place and made the perm ones to secure the intercooler in place.
6) Finally the pipes.

The whole thing took about 5 hrs for me (excluding 2 hours to weld the aluminium inlet then file it down)

By the way, I just got back from a long trip today. Fuel consumption seems to be better as well, I got 620km from ~52L of diesel, mainly on hwy at 100km/h

So the main purpose of the intercooler is to cool the air after the turbo and before the intake mainfold?
Brian

Yeah that is right, cooler air has more density. The air passes though the turbo is being heated up so it needs to be cooled down again. You probably don't need one at your place as its cold all year around javascript:void(0)

All right, thanks for the clarification