To: 80scool@yahoogroups.com From: "arv_fzj80" Date sent: Tue, 03 Sep 2002 05:03:04 -0000 Subject: Re: [80] HDJ80 - Intercooler issue (risk?considerations?) Send reply to: 80scool@yahoogroups.com In 80scool@y..., "Willem-Jan Markerink" wrote: > On 2 Sep 02 at 9:33, Vitor Costa wrote: > > > Hi > > I post this email in hope to read some opinions or advices. > > I put the possibility do do a home made intercooler for my HDJ80 42TD VX > > (1994). There is a house here that make custom intercoolers and radiators, I > > talked to them and they usualy do that for other cars, never done in a > > HDJ80. Since they will cost a 1/10 of a Safari kit here in Portugal I was > > considering this idea. > > I know that Safari comes with a nice complete kit I and I am buying only a > > custom intercooler. > > But I think that with less than 9/10 of the rest of the maney I will do the > > job... anyway I think it could be fun, but it is just a project didnt > > decided you If is worth time spent. > > 1/10 is indeed tempting....just be sure that they fabricate *and* > mount all parts to Cruiser/offroad quality.... > So first question: *what* other cars do they have experience with? > Small onroad 2wd's, or large offroad 4wd's? > > > Is there any risk/danger to build a oversized intercooler and cool to much > > the air? > > No. > However, you *could* block the air flow to normal radiator and > airco-radiator (if present). > (don't think you could add too much heat to the next radiators, but > airflow is essential) > You could of course mount a scoop, a hood-mounted intercooler....but > you won't get that done for 1/10 of the price....;)) > > > After the intercooler instalation, I think you need to do some gentle tweak? > > Yes, no increased performance if you don't tweak the fuel > pump....actually you probably even decrease performance, since you > add intake restriction by the lenght of the tubing/radiator path. > However, it's more than turning a screw, you want some internal parts > grinded down a bit, like they did with mine. A good dieselshop is > wanted here, preferably one who has experience with this kind of > rotary fuel pumps. > > > Anyone here have this procedures? Do I need to or is it ok just to install > > the intercooler? > > Just adding an intercooler will probably slightly decrease > performance, simply because of intake resistance (remember how much > effort/discussion is put into the least-restrictive air > filter!....this is just as significant!). > > You were in Spain, right? > In that case you are probably also subjected to an annual > exhaust-soot/particle test....something to keep in mind while > tweaking (if only to know how to tweak it back a bit > temporarily....;)). > --- Hi Vitor, I refer to message no.33385 of this board (the guy really seems to know a lot about your subject): Hi Guys on the web, 1HD-T and 1HD-FT engines all have their own specific "watch-out" area's when you start tuning. 1HD-T;You should go for an Intercooler because the injectors are in the dangerzone and cannot have much more temperature abuse as they already have.An Intercooler lowers the temperature on the nozzletip and therefor saves you from serious engine damage as well. 13103-17020 and 13103-17040,wich are oversize 1HD-T pistons,are fastmovers in the Toyota partsdept. You cannot use a carradiator as Intercooler,wich I saw done by a famous German tuner.Pressureloss in the system was 0,35Bar.Turbocharer couldn't handle the job and killed itsself.(at Toyota it costs only Euro 2640,-) You cannot use a small(BMW Accessorie cooler)watercooler as Intercooler because in the longrun it cannot cope with the chargetemperature and will,especially on freeways/motorways/autobahn,start to heat up your inlet temperature and turn your engine into a tjernobyl disaster.I saw this happen with another famous German tuner. Chiptuning is NOT possible with this engine.The only chip that is there,if you can find it,is in the electronic shiftprogram of the automatic gearbox.The only electronic part on the fuelpump is the potentioswitch that sends signals to the ECU of the automatic gearbox.Many customers had their 1HD-T CHIP-TUNED in Germany and France but I guess the fuelpump was "tweeked". Japanese 1HD-T engines had no EGR.EGR was firstly introduced on the 1HD-FT engine as of 9501. If you plan to work on the boost;Not higher than 0.8bar is recommended because your turbocharger will crash its turbinewheel.(It will loose a blade or 2 and many French customers agree with me). An Exhaustsystem from front to rear in 2,5inch can do a good job of about 7 horses. Another Camshaft will bring you some 10 extra horses and a better performance over 3000rpm. A well build,tuned,1HD-T engine,and I mean Intercooler,Exhaust,Turbocharger,Camshaft and upgraded/blueprinted fuelpump can bring you 240HP and 640N/M torque wich will last a long time and surprises you every day. 1HD-FT;Yes this engine has EGR,NO, removal will not bring 27HP (wrenching on the fuelpump does),Yes the engine feels sluggish because Toyota adjusted the flying turbinebladeproblem by reducing turbinespeed and therefor creating less performance out of this turbocharger,Yes the fuelpump runs leaner as well because its more an environmental diesel than the 1HD-T,Yes the EGR is to blame as well because fuelpumps on EGR engines are not set to enrich much under boostconditions,Yes the cilinderhead is capable of flowing a lot more than the 12valve 1HD-T. The injectors last longer than 1HD-T,they are more central in the combustionchamber and pistoncooling is a lot better than 1HD-T. An Intercooler is a good go,it can bring you easily 204HP and 430N/M torque. Setting up the boost to max 0,9bar in combination with some serious work on the pump does wonders however its better to blueprint this pump because they can be all over the place in settings. Exhaust the same as 1HD-T. A good combo of Intercooler,Sportturbocharger,Exhaustsystem and blue- printed fuelpump could bring you 280HP and 660N/M torque. Originalpartnumbers;00310-05500 Intercoolerkit 1HD-T 00310-06000 Intercoolerkit 1HD-FT Above partnumbers are from Toyota Netherlands were you could order your new car with intercooler including full warranty. Best regards, Maarten Verschure