I still have not upgraded the intercooler. Thinking of either a not too big front mount or making a thicker one for the original position. Even thinking of a water to air unit.
I did check air temps across the original, normal driving it coped ok, full throttle acceleration through the gears the outlet temp rose to over 140C. Sand or hard offroad driving would be similar high temps i would think.
Thanks. I will finish motor rebuild, and drive it for a bit.
But am thinking of Airtec or Allisport. Airtec is cheaper.
I have AC so will be double core option.
WTA IC has definite efficiency advantages. I guess I should look at that option. Im not sure if 200tdi Bosch injector pump has potential to deliver to make WTA potential worth while. I think double core ATA IC is about max potential for more power.
First was to replace the original with a thicker core unit, this made a noticeable difference in throttle response, the original is rather restrictive.
Second, and a lot of work, is the water to air unit. I cut down the original manifold, cleaned up the runners as they are rather restrictive with a large bump in the lower port section, and around the bolt holes.
Fitted a 600*200*50 radiator behind the grill, and a 12V auxiliary pump to circulate the coolant.
Engine is noticeably smoother with the large Plenum volume. I havent yet checked temps of intake charge, but after a run the exposed end of the water core are much colder than the rest of the
unit. Also much colder than the Outlet side of the air/air intercooler.
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