Date sent: Mon, 26 Jun 2000 11:33:56 +1000 To: 80_series@sgiblab.sgi.com From: Mark Woods Subject: [80] Intercooler installed on 1 HD-FT Send reply to: 80_series@sgiblab.sgi.com Well it has been a bit of a journey but I now have a Safari intercooler on my 1HD-FT and I am VERY VERY happy. It's a bit of a longish story so I will try to be brief and just hit the main points. It's a 1996 1 HD-FT manual with 120,000 Km, injectors and valve clearances were done at 112,000 Km and I was getting 11.5-12.5L/100Km, blowing more smoke than I was comfortable with, had annoying ticking sounds at around 1100 and 2200 rpm and to top it off it was not making good power above 3000 rpm. However, power did seem to be good from 1000 - 3000 rpm though perhaps a bit jerky if in too high a gear and below 1800 rpm. As an aside, I had approached Toyota regarding the ticking and my lack of power at high rpm and not being able to redline it. Which only resulted in one very dissatisfied customer. So I thought an intercooler would be the way to go. At least it should help with increasing the power and reducing the smoke. Well I have to honest and say I was not all that happy when I first drove away with my new intercooler on. Sure the smoke was significantly reduced and the 1000 - 2000 rpm range was silky smooth, but the top end was very disappointing. To Safari's credit they did say that they felt there was something wrong with the fuel pump and that they couldn't get any more performance out of the engine without risking damage to the engine in the long term. This is certainly a philosophy I would follow. So, based on a recommendation from Safari, I booked my L/C in for a fuel pump recalibration at B.J. Diesel in Dandenong (Melbourne, Australia). This changed a few things but by far the biggest change was the HUGE improvement to the top end power. Apparently the internal timing was not advancing! Also, as a side issue, the ticking sounds have gone! Finally, I took it back to Safari for a retune. This time I was fairly confident of a good result but what I actually got was a FANTASTIC result. Heaps of real smooth power that just keeps on coming with hardly a trace of smoke. I was very impressed with Safari going the extra distance with me on this troublesome install. I can highly recommend Safari and B.J. Diesel for quality work and a high level of customer service. here's the stats (just for Mick Barson): Fuel consumption: 10-11L/100 Km (now) c.f. 11 - 12L/100Km (before) 27 % increase in the min torque 24 % increase in max torque my min torque now is greater than my max torque was before! On Safari's 4wd dyno max power was104 Kw @ 3500 rpm and max torque 3900 N @ 2350 rpm (actually, it's > 3800N from 2100 - 2900 rpm) regards Mark Woods From: "Willem-Jan Markerink" To: 80_series@sgiblab.sgi.com Date sent: Mon, 26 Jun 2000 12:30:35 +0100 Subject: Re: [80] Intercooler installed on 1 HD-FT Send reply to: 80_series@sgiblab.sgi.com On 26 Jun 00 at 11:33, Mark Woods wrote: > Finally, I took it back to Safari for a retune. This time I was fairly > confident of a good result but what I actually got was a FANTASTIC result. > Heaps of real smooth power that just keeps on coming with hardly a trace of > smoke. > > I was very impressed with Safari going the extra distance with me on this > troublesome install. I can highly recommend Safari and B.J. Diesel for quality > work and a high level of customer service. > > here's the stats (just for Mick Barson): > Fuel consumption: 10-11L/100 Km (now) c.f. 11 - 12L/100Km (before) > 27 % increase in the min torque > 24 % increase in max torque > my min torque now is greater than my max torque was before! > On Safari's 4wd dyno max power was104 Kw @ 3500 rpm and max torque 3900 N @ > 2350 rpm (actually, it's > 3800N from 2100 - 2900 rpm) Congratulations on this 'better-than-factory' job! But mate, there is something seriously missing here....you never mentioned a larger exhaust!....;-)) So you either forgot to mention it, or your trouser better have some stitches left....:-)) Consider an all-custom job, 3", welded on the spot....I believe you can't go larger than 2.5" without getting stuck when mounting it....it has to be welded piece-meal wise....not cheap, but the 1HD-FT loves every bit of air it can get or get rid of....;-)) PS: did you already have a snorkel? I believe Safari recommend one in case of an intercooler....but that's also the case for a better exhaust, so all my above rambling might be mooth..... -- Bye, Willem-Jan Markerink The desire to understand is sometimes far less intelligent than the inability to understand [note: 'a-one' & 'en-el'!] Date sent: Tue, 27 Jun 2000 08:07:23 +1000 To: 80_series@sgiblab.sgi.com From: Mark Woods Subject: Re: [80] Intercooler installed on 1 HD-FT Send reply to: 80_series@sgiblab.sgi.com >Congratulations on this 'better-than-factory' job! >But mate, there is something seriously missing here....you never >mentioned a larger exhaust!....;-)) You're right, I didn't! That was last years mod and is probably the reason the turbo spins up so FAST. :-) My exhaust is 3" to a straight through barrel muffler (no resonator) and stock exhaust out the back. I believe this is a great compromise between noise and power. regards Mark Woods From: "Bob Reaburn" To: <80_series@sgiblab.sgi.com> Subject: Re: [80] Intercooler installed on 1 HD-FT Date sent: Tue, 27 Jun 2000 23:14:53 +1000 Send reply to: 80_series@sgiblab.sgi.com [SNIPPO] > Congratulations on this 'better-than-factory' job! > But mate, there is something seriously missing here....you never > mentioned a larger exhaust!....;-)) > So you either forgot to mention it, or your trouser better have some > stitches left....:-)) > > Consider an all-custom job, 3", welded on the spot....I believe you can't > go larger than 2.5" without getting stuck when mounting it....it has > to be welded piece-meal wise....not cheap, but the 1HD-FT loves every > bit of air it can get or get rid of....;-)) > > PS: did you already have a snorkel? > I believe Safari recommend one in case of an intercooler....but > that's also the case for a better exhaust, so all my above rambling > might be mooth..... > -- > Bye, > > Willem-Jan Markerink My HD-T has a Safari 3" sytem fitted - 3" throughout. It has a single muffler and slip joint over the rear axle. Very easy to fit and when when added to a stock HD-T (no intercooler at that stage), it added about 6 kW. Cheers, Bob Reaburn HDJ80 - Bendigo (Downunder) From: "Willem-Jan Markerink" To: 80_series@sgiblab.sgi.com Date sent: Tue, 27 Jun 2000 14:18:31 +0100 Subject: Re: [80] Intercooler installed on 1 HD-FT Send reply to: 80_series@sgiblab.sgi.com On 27 Jun 00 at 8:07, Mark Woods wrote: > >Congratulations on this 'better-than-factory' job! > >But mate, there is something seriously missing here....you never > >mentioned a larger exhaust!....;-)) > > You're right, I didn't! That was last years mod and is probably the reason the > turbo spins up so FAST. :-) My exhaust is 3" to a straight through barrel > muffler (no resonator) and stock exhaust out the back. I believe this is a > great compromise between noise and power. Do you mean stock including the goose-neck bends over the rear cross member? I thought that was the most restrictive part of the stock system (and the main problem when going from 2.5" to 3", as it can't be wiggled into place anymore, but has to be welded on the spot). Stock diameter is 2", not? -- Bye, Willem-Jan Markerink The desire to understand is sometimes far less intelligent than the inability to understand [note: 'a-one' & 'en-el'!] Date sent: Wed, 28 Jun 2000 09:09:00 +1000 To: 80_series@sgiblab.sgi.com From: Mark Woods Subject: Re: [80] Intercooler installed on 1 HD-FT Send reply to: 80_series@sgiblab.sgi.com >Do you mean stock including the goose-neck bends over the rear cross >member? Yes. >I thought that was the most restrictive part of the stock >system (and the main problem when going from 2.5" to 3", as it can't >be wiggled into place anymore, but has to be welded on the spot). >Stock diameter is 2", not? You may be correct, however, replacing the factory muffler etc with straight through 3" pipe and muffler made a very noticable improvement. The exhaust people said that a 3" back end was going to make more noise. I didn't want that. regards Mark Woods From: "Greg Goulden" Date sent: Wed, 28 Jun 2000 14:10:25 +1000 To: 80_series@sgiblab.sgi.com Subject: Re: [80] 3" exhaust [was Intercooler installed on 1 HD-FT] Send reply to: 80_series@sgiblab.sgi.com >Do you mean stock including the goose-neck bends over the rear cross >member? >Yes. That's a pity cause it does get a bit squashy around there. Pretty tight getting the old system flange out between the floor and cross member. Bob said his had a slip joint there, however my 3" Safari has a 2 bolt flange just like the original system. >I thought that was the most restrictive part of the stock >system (and the main problem when going from 2.5" to 3", as it can't >be wiggled into place anymore, but has to be welded on the spot). >Stock diameter is 2", not? >You may be correct, however, replacing the factory muffler etc with >straight through 3" pipe and muffler made a very noticable >improvement. The >exhaust people said that a 3" back end was going to >make more noise. I didn't >want that. The original system is restrictive. The combination of pipe size and also the fact that as soon as the pipe enters inside the original main muffler it is reduced to around 1.5" is quite restrictive. It is this reason which a mate's stock 1HZ with just a main muffler change goes so damm well!! Good power and economy. I only found this out recently when another mates Safari turbo'ed 1HZ exhaust broke at the inlet to the main muffler because the mounting bracket on the Safari front pipe broke and we didn't know till it was too late!!! The complete Safari 3" system is not noisey. It is only when the flexible joint up the front is cracked it snuffles at idle. Original flex joint never broke, Safari joint 3.5 years old and stuffed. Regards, Greg Goulden 1990 HDJ80 VX TD-I Melb. Aust. From: "Bob Reaburn" To: <80_series@sgiblab.sgi.com> Subject: Re: [80] Intercooler installed on 1 HD-FT Date sent: Wed, 28 Jun 2000 13:05:50 +1000 Send reply to: 80_series@sgiblab.sgi.com > > Well it has been a bit of a journey but I now have a Safari intercooler on > my 1HD-FT and I am VERY VERY happy. It's a bit of a longish story so I will > try to be brief and just hit the main points. > > It's a 1996 1 HD-FT manual with 120,000 Km, injectors and valve clearances > were done at 112,000 Km and I was getting 11.5-12.5L/100Km, blowing more > smoke than I was comfortable with, had annoying ticking sounds at around > 1100 and 2200 rpm and to top it off it was not making good power above 3000 > rpm. However, power did seem to be good from 1000 - 3000 rpm though perhaps > a bit jerky if in too high a gear and below 1800 rpm. As an aside, I had > approached Toyota regarding the ticking and my lack of power at high rpm > and not being able to redline it. Which only resulted in one very > dissatisfied customer. > > So I thought an intercooler would be the way to go. At least it should help > with increasing the power and reducing the smoke. Well I have to honest and > say I was not all that happy when I first drove away with my new > intercooler on. Sure the smoke was significantly reduced and the 1000 - > 2000 rpm range was silky smooth, but the top end was very disappointing. To > Safari's credit they did say that they felt there was something wrong with > the fuel pump and that they couldn't get any more performance out of the > engine without risking damage to the engine in the long term. This is > certainly a philosophy I would follow. So, based on a recommendation from > Safari, I booked my L/C in for a fuel pump recalibration at B.J. Diesel in > Dandenong (Melbourne, Australia). This changed a few things but by far the > biggest change was the HUGE improvement to the top end power. Apparently > the internal timing was not advancing! Also, as a side issue, the ticking > sounds have gone! > > Finally, I took it back to Safari for a retune. This time I was fairly > confident of a good result but what I actually got was a FANTASTIC result. > Heaps of real smooth power that just keeps on coming with hardly a trace of > smoke. > > I was very impressed with Safari going the extra distance with me on this > troublesome install. I can highly recommend Safari and B.J. Diesel for > quality work and a high level of customer service. > > here's the stats (just for Mick Barson): > Fuel consumption: 10-11L/100 Km (now) c.f. 11 - 12L/100Km (before) > 27 % increase in the min torque > 24 % increase in max torque > my min torque now is greater than my max torque was before! > On Safari's 4wd dyno max power was104 Kw @ 3500 rpm and max torque 3900 N @ > 2350 rpm (actually, it's > 3800N from 2100 - 2900 rpm) > > regards > Mark Woods I would like to endorse Marks words - his experience with the intercooler closely matches mine. If you are contemplating fitting an intercooler, get the pump and injectors checked out first. Be careful who does the work, I took my vehicle to 3 different 'experts' before going to BJ Diesel. I highly recommend BJ, they know what they're doing, their rates are reasonable and they care about customer satisfaction. I might add that I found Safari also to very professional and helpful in getting my 80 sorted out. As a bonus, Safari's tea 'lady' who goes by the curious name George, although too hairy for my liking and being severely beauty challenged, makes a good cuppa! Cheers, Bob Reaburn HDJ80 - Bendigo (Downunder) From: "George Couyant" To: <80_series@sgiblab.sgi.com> Subject: Re: [80] Intercooler installed on 1 HD-FT Date sent: Thu, 29 Jun 2000 00:44:49 +1000 Send reply to: 80_series@sgiblab.sgi.com > My HD-T has a Safari 3" sytem fitted - 3" throughout. It has a single > muffler and slip joint over the rear axle. Very easy to fit and when > when added to a stock HD-T (no intercooler at that stage), it Umm, that's a really early model exhaust. Not like that any more. Cheers gc '97 HDJ80 - Melbourne Oz From: "George Couyant" To: <80_series@sgiblab.sgi.com> Subject: Re: [80] Intercooler installed on 1 HD-FT Date sent: Thu, 29 Jun 2000 00:46:41 +1000 Send reply to: 80_series@sgiblab.sgi.com > Do you mean stock including the goose-neck bends over the rear cross > member? I thought that was the most restrictive part of the stock I was surprised to see what little effect that squashed area had on performance. Bugger all really. It's the muffler that is restrictive. Cheers gc '97 HDJ80 - Melbourne Oz