Intercooler upgrade - D3.

[loanrangie]

Thinking about an IC upgrade but not one of those expensive alisport etc brands, i have seen some universal fit types that are 600mmx300x100mm that look like a reasonable fit.
Anyone fit one this size ?

[DazzaTD5]

*Britpart do one, I think from memory it had a alisport label on it.
*I have only fitted two, one of them recently to our project D3 i had to trim the inner mount of the ARB bullbar.
*it was one i had in stock for about 5 years, so dont know what they are priced like now.
*does it make a difference? prolly not much, but i did the egr *cough* thing, ceramic exhaust manifolds and crossover pipe, tuned it, and anything else i could think of so the combination of doing everything is good.
*the end result in performance is it would likely eat a D4 3.0 off through most of the rev range. (will have to try it out)

DA4635

[loanrangie]

*Britpart do one, I think from memory it had a alisport label on it.
*I have only fitted two, one of them recently to our project D3 i had to trim the inner mount of the ARB bullbar.
*it was one i had in stock for about 5 years, so dont know what they are priced like now.
*does it make a difference? prolly not much, but i did the egr *cough* thing, ceramic exhaust manifolds and crossover pipe, tuned it, and anything else i could think of so the combination of doing everything is good.
*the end result in performance is it would likely eat a D4 3.0 off through most of the rev range. (will have to try it out)

DA4635

How it will fit with a bullbar would be my main concern, will need to have a look at my mates wreck and check the clearance.

[Airmech953]

How it will fit with a bullbar would be my main concern, will need to have a look at my mates wreck and check the clearance.
The wreck has gone! The CFA are using it for road crash rescue training. Comment was that they don't get many luxury cars to train on.

[loanrangie]

The wreck has gone! The CFA are using it for road crash rescue training. Comment was that they don't get many luxury cars to train on.

bugger, was going to see what parts were left that may be good. Oh well, i'll just remove the grill and get the tape measure out.

[DazzaTD5]

its easy... so you have the 4 bolts on each side that the orig bumper bolts to or the brackets for the arb bar bolt.
the intercooler bolts between the chassis ends and the bracket for the bullbar, it uses the 2 inner bolts on each side, the outer 2 bolts have a spacer the same thickness as the cooler mount.

the cooler is very wide and the bullbar mounts, the flat part which has the bolt holes, the edge of it hits the tanks on each end of the cooler, all you do is grind off a bit from the bullbar mounts.

for some odd reason i dont have any pics of the whole D3 project, prolly because it had been in pieces for so many years it was racking my brain to get the whole vehicle back together and running.

[DazzaTD5]

in this egr hose routing video, round 8:29 on there is a view of the intercooler and you just see the mounts...

https://youtu.be/9aGqDLKHmos?feature=shared

[loanrangie]

I now have an RS500 IC ready to fit, just awaiting delivery of a couple of silicone hose joiners and a length of alloy intake pipe then the fun begins.
I'll see how it fits as is but might have the inlet/outlet modded so that they are straight.


https://files.ekmcdn.com/toyosportsltd/images/fmic-intercooler-ford-sierra-escort-cosworth-rs500-162.99-843-p.jpg

[loanrangie]

Now have the joiners and I might just get the inlet/outlet modified before I attempt to fit it.https://uploads.tapatalk-cdn.com/20250918/3249af57137300e4ea5b5333235d2b43.jpghttps://uploads.tapatalk-cdn.com/20250918/25a2d1af381d1b6c158d457aeedce86e.jpg