My Intercooler set up on my 300SD
 

I mentioned doing this when i first bought my 300sd. finally this morning i started the project. and its now done. Ill post some pics as wells as a list of parts.

That was a quick install! I wish my intercooler would go in that quickly. Did you use a air/air IC or a air/water unit? How much did it decrease your EGTs? Any plans to adjust the full load of the IP? Any idea of the pressure drop across the core? :dizzy2:

i used a air to air unit. its the old one off of my Eclipse. to tell you the truth i cant tell a difference except for a little more turbo lag i dont have anything to monitor the engine with so i cant say much more then what i feel in the seat.

if you have a stp by step that would be awesome. I have an intercooler, but no idea where to start. how hard was it to disconnect the turbo and intake? did you use the stock intake? how did you get it all hooked up? I'm all ears and have a ton of questions :D

the turbo and intake arent bolted together. all you really have to do is (simplified explaintion) you loosen the bolts on the compressor housing, then turn it so it faces the passenger side of the car, then using silicone couplers and 2 inch pipe you route from the turbo to the intercooler, then back out into the intake using a silicone coupler on the intake as well.

did you have to move the intake at all to make the turning of the turbo possable?

no, what you do is loosen all four bolts on the exaust manifold so you can pull the turbo far enough out that it clears the intake flange.

Where did you mount the intercooler? There doesn't seem to be a great spot to mount a air/air unit and get a good airflow over it, hence why I went with a air/water unit.

How did you modify the intake manifold? I just sen't mine to the welder yesterday to have a 2.5 inch hose barb attached.

You probably don't notice any gains because you are not burning any more fuel. You must turn up the full load (an internal adjustment in the injection pump) to gain power. Before you adjust full load I recommend installing a pyrometer.

See my pyrometer how to here: http://www.peachparts.com/shopforum/diesel-discussion/167588-pyrometer-thermocouple-installation-pictorial.html?highlight=pyrometer+pictorial

Full Load adjustment here: http://schumanautomotive.com/forums/showthread.php?t=1205

http://i76.photobucket.com/albums/j3...cooled0003.jpg
http://i76.photobucket.com/albums/j3...cooled0002.jpg
http://i76.photobucket.com/albums/j3...cooled0007.jpg
http://i76.photobucket.com/albums/j3...cooled0004.jpg

Does the car actually perform any different? Looks to me like an intercooler in a place where no airflow will really get to it, and one of those K&N "I want to destroy my engine" cone filters. If you didn't adjust the fuel quantity or install an EGT gauge there will likely only be a decrease in performance. I vote for the stock setup.

the intercooler will still do its job. just less effecently. its still cooling the charge. if it were a front mount then it would take even longer. so since this one has less piping it will spool sooner then a FMIC and make up for its placment

No, no it won't. The whole point of an intercooler is to allow more fuel to be burned while keeping IAT (intake air temperature) in check which has two benefits: Cooler air is denser and reducing EGT (exhaust gas temperature) from the extra fuel. The amount of turbo lag is inconsequential.

The placement of the intercooler is poor but obviously was choosen as it is the easiest. There is little or no airflow through the intercooler core in that location so the intercooler will heat soak in a very short time and then will provide no benefit at all. If you truely want that location to work then consider installing an electric fan to move air across the core.

If you don't believe me then go get an IAT gauge, Autometer makes one, and do a little pre and post intercooler testing for yourself.

Now let me congratulate you on doing a decent job on the installation. Its nice to see someone thinking outside the box from stock. I say go back to the project, improve the installation, quantify the gains/benefits, and then let us know.

RT

put a fan on it. I know its going to blow hot air thought the intercooler... but it is better then no airflow. the intercooler is cooling the air, some what, but with out airflow there is nothing to carry the heat away from the intercooler.

i was thinking of doing something similar but with a fan. i want even better air flow, but i haven't come up with anything yet. I don't want to delete my fog light because some day i'll get some euro lights, and under the car is not an option. but if i come up with something i'll post it.


pawoSD, I have one of those "K&N "I want to destroy my engine" cone filters" I've put about 80,000 miles on the car running that style filter, i clean it and change it as needed. no problems thus far.

310,000 miles on the car... almost to my 500,000 Km award!

Another reason to install a intercooler is to lower the temps in the engine- which will increase the engines life span. I know I know- these engines already run forever... but if you can do it- why not? It's better than sitting on the couch eating chips. You will need to move some air over the IC somehow- but I'd gues s as is it will provide lower temps in a small percentage.

I bet you'll see some performance gains in the summer time when it's really hot out. You'll need to get some airflow across that intercooler. Good Job!