Bigger Intercooler .

[Fusion]

Thinking of upgrading the intercooler in the D1 . For the money they are worth . Do they make much of a difference in power ?

[Tombie]

Thinking of upgrading the intercooler in the D1 . For the money they are worth . Do they make much of a difference in power ?

Give TRS a call in SA... off the shelf...

or Direct to my manufacturer...

ASE Turbo...

ASETurbo (http://www.aseturbo.com.au)

[lewy]

been playing with the idea myself,however $1200 on a 93 200tdi is out of the question,what about a second hand intercooler from a td5,Are they any better etc

[Rangier Rover]

Welcome back:D, I have driven disco owner's 300 with the bigger intercooler. I think he may have had the pump tweaked. Anyway it goes quite well for a 300 tdi. To get any more probably would involve changing turbo I would imagine.

[big guy]

As said above, I did mine at TRS for $595. New silicone hoses for $250 and a pump tweak.
Definately worth it.
Make sure pump gets done via a EGT gauge so you don't exceed 500degrees or something but it now pulls way better even under load up hills.
They are not bigger just better.
They flow better, cool better etc. They fit in same place.

My new hoses made a big difference, I am not sure why they did, old ones were still O.K, no delaminating or anything.

[dullbird]

I have a bigger intercooler and silcome hoses and a pump tweek, before the suspected head gasket failure my car pulled pretty hard.....and was fairly quick off the line for a 300 Auto:)

[Panya]

Depends how you adjust the pump. Either pulls better or better economy. D1 200tdi with bigger intercooler is now nuclear powered it takes so long to need to fill up, Defender 300 with intercooler pulls better with same economy.

[omvanders]

I have the TRS upgrade version... together with a dynotune it was way better (70.3kw at the wheels).

Mind you I also noticed a further significant improvement when I then had the timing belt replaced, both in terms of pulling power and a reduction in black smoke emitted under heavy load.

Spot on timing shouldn't be under-rated. Maybe if I'd had the timing belt done first I might not have felt the need to do the intercooler as well?!

[PAT303]

Can you recore the original?. Pat

[HBWC]

why have people got a biger air to air?
i thought a water to air would be the next step
with in the next 12 months(if money alows)
im going to build a water to air as part of my air intake manifold
once my vnt turbo goes on

[Fusion]

Thanks Guys ! Does anyone know of a place in Vic where i can get the injector pump tweaked ?

[nzlandies]

Can you recore the original?. Pat

This is what I did. I put the biggest core I could fit on the existing tanks. We flowed the tanks as well removing heaps of metal and making the inlet and out let quite a bit bigger. Yes there was a very noticeable difference. I had to cut the cowling away from behind it so it would fit properly. I had actually done this way before the upgrade and was surprising that this heaped a bit as well. The theory was that the air could blast through it faster and cool better. It did!

Fuel pump tweaks are easy. Just do it your self.i

The 200-300 is incredibly easy to tweak. I have done mine and countless others. and all needed to be done differently, some were auto discos others defender 110 etc and owners wanted different things so its good to know how its done so you can do what suits you.

A handy mod to start with is replace the screws on top of the pump with allan key cap screws. This makes it much easier and quicker when you are fine tuning, you will be in and out of it a few times before you are happy. Leave the torx screw on the top alone and never play with max fuel screw on the side, the less things you muck about with the better and makes its easier to fine tune and fix messes.

Pull off the top and note and mark the position of the small dot at about 12 o'clock then remove the diaphragm. It will come out but you may need to move the throttle to free it.

Give star the star wheel one half turn to the right, this allows more fuel with boost.

On the shaft of the diaphragm there is plastic bush. Remove and keep in a safe place. basically this lets the diagram go down further. Some shave it down if they don't want to go the whole way, but who doesn't want to go all the way!

Replace diaphragm with the small point back where it was.

Put the top back on and go for a spin.

If its blowing no smoke and you still want more power, then you can take the top off the pump and by small degrees turn the diaphragm to the right untill it produces no more than a very slight haze at full noise, if any more smoke than this then turn the other way. If the smoke is at low revs then turn the star wheel back anti clockwise as it can give additional fuel at low boost too early or too much fuel is being added.

I have mine tuned for a bit of smoke under load at low revs which is very handy when you are climbing a steep hill off road or about to stall, it then clears up totally clean as soon as boost kicks in and then a very light haze all maxed. If its blowing any black you will end out loving the power. Tough titty, turn it back, even if it seems gutless by comparison, black smoke at load shags heads!

Without a big intercooler then maybe don't even have a haze at high revs but a bit of low rev smoke (under 1500 or until its boosting) wont kill it.

if you want to tweak the boost there no point in going over 18psi as restrictions in the overall airflow means you will loose power beyond this.

REMEMBER AND NOTE EVERYTHING so you can put it back exactly as you found it if need to or if you get cocked up. Mark the point and count the clicks! As every ones says an EGT gauge never hurts and your radiator needs to be in top notch order. Seriously this is a Hanes 2spanner job.

Buy the way these tweaks are what Jeremy J Fearn does. google him if you dont know who he is.

I have done heaps of these and never cracked a head yet and you will be fine if just don't over do it.

Have fun

[Fusion]

Found a small problem with the diaphragm with a small tear in it :mad::( . So i'm guessing it's not working to it's full potential . better make a phone call ;) .

[Fusion]

Replaced the diaphram and it went great guns ! the last one must of been torn when i bought it . It has even changed the note of the disco :eek::cool: .

Then done a little tweaking and have gained some power but have not gone over the top with adjustments . Very happy with what i have now :twisted: Lets hit the hills :twisted::twisted::twisted::twisted::cool:;)

[nzlandies]

Pleased you are happy, its not hard when you know how. Have fun!!

[markb]

Give TRS a call in SA... off the shelf...

or Direct to my manufacturer...

ASE Turbo...

ASETurbo (http://www.aseturbo.com.au)

Is the TRS Intercooler the same as the ASE Intercooler as there is a big
Difference in price between the two. Is one better than the other?

[Narangga]

Is the TRS Intercooler the same as the ASE Intercooler as there is a big
Difference in price between the two. Is one better than the other?

I believe TRS source theirs from ASE.

[bblaze]

I have just got one off ASE, paid $550 for the new one with a $200 exchange fee, if you send them yours you dont have to pay the $200 fee (must send the old one back)
cheers
blaze

[Jeff]

On the TRS website it mentions nothing about exchange, maybe that is why there is a price difference.

Jeff

:rocket:

[rangieman]

I have just got one off ASE, paid $550 for the new one with a $200 exchange fee, if you send them yours you dont have to pay the $200 fee (must send the old one back)
cheers
blaze
cheers mate:cool:

[Pedro]

My Dear friends have you not heard of ebay you can get a re cored inter cooler with tuning can give 20% more power for 550 plus post from british 4x4 in tazie. Or a full sized one for 650 which will give you 35% more power but of course only if you have your turbo boost increased and pump tuned. But in doing so i would think about bonnet vents to draw more air through radiator ect and blocking off the gap where the pipes go through. Changing my injectors made the biggest difference i think.:p

[51jay]

I have a 600mmx300x75 front mount intercooler on mine with 75mm outlets, a bit of a pain to plumb but works very well with a big downpipe and E.S 2.8 VNT turbo, its not quite twice as big as the TDi300 turbo. i/c cost $150 from memory its been 2 or 3 years now. Haven't had any problems since I bit the bullet and installed everything properly. Oh! apart from a burst oil hose which resulted in a new factory long motor.