 | Home > Tdi > Installing a bigger inter-cooler? |
 
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| Kit Member Since: 12 Feb 2016 Location: Shropshire Posts: 1110   
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Has anyone here fitted a larger universal intercooler to their Tdi?
I've been looking at a few options: 1) Allisport full size: I don't really like the idea of removing the front tie in bars, that means building brackets and moving the radiator, I don't mind paying £400+ for a purpose built bolt on solution... but if I have to start modifying things then I no longer see the value. 2) Higher capacity version using OEM fittings: I like this for no fuss and a small performance increase http://www.ebay.co.uk/itm/162242354310?_tr...EBIDX%3AIT 
3) Full size "universal" front mounted intercooler: I quite like the idea of fabricating my own bits to fit one of these but I was wondering if anyone else has done something similar? 1993 200 Tdi 90 CSW
1956 Series 1 Hard-top 1958 Series 1 Soft-top |
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13th Apr 2017 8:18am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Hi Kit. Yes I have fitted a full sized intercooler to my 200tdi. You a re quite right it is irritating that the support brackets are removed as well as the anti burst finger catch (hits the top of a full sized intercooler). I got over this by removing the anti burst catch and bonnet striker and fitting a set of external bonnet catches like the series military or Jeep Wrangler ones. Perfect solution as you no longer need to slam the bonnet down so the cross struts are not required.
Don't be in a rush to go full size... With 200tdi engines you can get soooo much more out of utilising just the original intercooler (cleaning it inside and out is a must) and adjusting the pump and turbo boost pressure to match. You will find that the standard pump is very de-tuned and a slight adjustment makes a massive improvement to power and drivability. At this stage a 90 will go like stink and be an incredibly fun drive. Smiles for miles... 
If after doing this you feel you want more, then look to an intercooler, either the OEM with larger core or full sized it is up to you. You will have to re-tune the pump and turbo boost pressure to match. A TDI is a great and forgiving engine to work on, the ultimate DIY'er package when combined with a defender IMHO... There is nothing you cannot do on this engine! If you want more info on tuning a TDI I will post some links for you to scan through. |
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13th Apr 2017 9:08am |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Hi Kit. I do somewhere. I will have to dig them out for you
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13th Apr 2017 5:49pm |
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| Kit Member Since: 12 Feb 2016 Location: Shropshire Posts: 1110
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Good man
1993 200 Tdi 90 CSW
1956 Series 1 Hard-top 1958 Series 1 Soft-top |
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13th Apr 2017 6:31pm |
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| jst Member Since: 14 Jan 2008 Location: Taunton Posts: 8172  
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there is a pdf document in my gallery on tdi pump adjustments.
get an egt, then adjust the pump settings then if you want more get the intercooler and adjust again. Cheers James 110 2010 XS Utility 130 2011 M57 bespoke Camper 90 2010 Hardtop 90 M57 1988 Hardtop |
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13th Apr 2017 9:24pm |
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| Kit Member Since: 12 Feb 2016 Location: Shropshire Posts: 1110
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Downloaded, cheers
1993 200 Tdi 90 CSW
1956 Series 1 Hard-top 1958 Series 1 Soft-top |
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14th Apr 2017 2:26pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203 
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Hi Kit, looks like you've been sorted by the knowledgeable people on here!
I've got the second Intercooler you posted in my 90. It's tight but it'll fit. Pushing close to 30psi through it, the pipe between the cooler and intake manifold is often very cold after a hard run, it's a beast for sure. If you want any details or better pics just let me know dude. Cheers |
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28th Apr 2017 10:17pm |
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| jst Member Since: 14 Jan 2008 Location: Taunton Posts: 8172
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30psi on what lump? Cheers
James 110 2010 XS Utility 130 2011 M57 bespoke Camper 90 2010 Hardtop 90 M57 1988 Hardtop |
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30th Apr 2017 7:51pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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200tdi
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30th Apr 2017 7:59pm |
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| Kit Member Since: 12 Feb 2016 Location: Shropshire Posts: 1110
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It's a little way off for me, in reality were probably talking next year... but it'd be really good if you could post details and pics here or in your own thread so I can make a really good job of mine (your install looks very tidy)? 1993 200 Tdi 90 CSW 1956 Series 1 Hard-top 1958 Series 1 Soft-top |
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1st May 2017 7:24pm |
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| okami Member Since: 06 Apr 2017 Location: Hertfordshire Posts: 90 
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So following the same thread as OP's post, has anyone done a comparison between the Allisport double core and the ebay equivalent?
https://www.allisport.com/shop/performance...tercooler/ vs http://www.ebay.co.uk/itm/115MM-UPGRADE-IN...SwV0RXwAbx I have no doubt that the Aliisport is better designed and probably higher quality, but is it really worth three times more? |
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2nd May 2017 11:01pm |
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| steveyorks Member Since: 08 Apr 2013 Location: west yorkshire Posts: 185  
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I had an Alisport intercooler on my last 200tdi. To be honest I would not bother to replace the standard one. For the money you need to spend the gains are minimal. I echo the previous poster who stated the fuel pump adjustment makes the majority of difference.
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21st Jul 2017 8:16pm |
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| steveyorks Member Since: 08 Apr 2013 Location: west yorkshire Posts: 185
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I had an Alisport intercooler on my last 200tdi. To be honest I would not bother to replace the standard one. For the money you need to spend the gains are minimal. I echo the previous poster who stated the fuel pump adjustment makes the majority of difference.
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21st Jul 2017 8:53pm |
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| Procta Member Since: 03 Dec 2016 Location: Sunderland Posts: 5240
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sorry to hijack, are the 300s Detuned like these? also tuning the TDI does that make them better mpg wise? Defender TD5 90 ---/--- Peugeot 306 HDI hatch back
Success is 90% Inspiration and 4 minutes Preparation # you can make it! |
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23rd Jul 2017 9:57pm |
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