Master
I got myself an Allisport direct replacement intercooler for my 300tdi. I managed to get the top panel off the radiator/IC frame, but I couldn't get the old IC out due to the fan shroud fouling on the bottom IC pipe. I don't have a way to remove the fan. The frame also has rolled edges (vertical) that I think may need to be cut off to allow for the wider core of the new IC. My question is, has anyone fitted one of these, and what problems were encountered? were the benefits worth it? It was described as a direct drop in replacement, but it looks like I will need to do a substantial amout of work to get it in. I hope that it does as described, and gives me up to a 25% increase in power/torque, and helps with my fuel economy, which isn't too bad now. Cheers.
I just took mine out for a clean recently. The shroud will bend enough just need to get the bottom pipe up past it, don't be shy. I bent that top angle up with some pliers cause there wasn't enough room. When you reassemble bolt top cover to the bent bit first then use the cover to lever it down, that way you can't slip and damage your new shiny bit!
A fan spanner is 32mm for that car, left thread, 20 bucks or so depending where you go
Moderator
I hate to say it but only in your wildest dreams.Originally Posted by micksta1973
You'll need to adjust the pump fuel delivery to get any meaningful power increase and this is where the bigger I/C will definitely help otherwise it'd be hard to tell.
Master
Installed my Allisport double core intercooler in my 200tdi last week and had it dynotuned today with full fuel and boost pressure setting.
My radiator frame needed to be modified with the edges of the frame cut off on the intercooler side.
The standard numbers are with the uprated intercooler already installed, but nothing else touched. With a professional tuning the results are Approx. 54hp to 69hp = 27.7% increase in power
455lb to 590lb = 29.6% increase in torque.
A worthy increase
YarnMaster
SupporterBushman83
What boost pressure and EGTs under load are you running to get those figures???
Steve
'95 130 dual cab fender (gone to a better universe)
'10 130 dual cab fender (getting to know it's neurons)
OldBushie
I had a similar increase by fitting gas injection to my Tdi,until number two injector seal failed coming back from Perth last thursday,she chuff chuffed herself all the way home. Pat
Master
Boost is set to 12psi and my EGT's have reached 450 degrees celsius driving around town with fast acceleration while I test out what she can do... is certainly a difference.
Master
Bushy, just to clarify. you fitted a direct replacement I/C, not a full front mount? if so, it would seem I'll have to do a wee bit of grinding as well, bugger, so much for a direct replacement. looks like the power increase will be worth the work tho. what brand did you fit? cheers.
Master
I fitted the Allisport double core intercooler (80% more surface area) which has the same width and length as the standard but is deeper so the 2 lips on the intercooler side of the radiator mounting frame needed to be cut off so it wouldn't foul. If you bought the direct replacement version which gives 50% greater surface area you may be ok. Check out my other post here for pics : http://www.aulro.com/afvb/projects-t...r-build-5.html
To get the full power out of it get your car dyno'd. I installed it first and didn't change anything and there was very little difference... but with a professional tune of the turbo and fuel anneroid .. my god!
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