Intercooler for the 2.5

ChrisF · Post by **ChrisF** » Tue May 08, 2012 7:06 pm

I know there are a various threads of intercoolers on this forum. But can we get some info together on a single thread (asseblief manne)

Please tell what intercooler you used

where did you get the pipes

What chip did you use with it

who did this work for you (either the full installation or just the chip setup at the end)

I want to do this to ELDERS when the warrantee expires, or maybe a bit earlier.

THANKS :)

OOOOMS · Post by **OOOOMS** » Tue May 08, 2012 7:27 pm

Please tell what intercooler you used - Mzda 2.5 drifter (free)

where did you get the pipes (Toy supplied)

What chip did you use with it (Dastek)

who did this work for you (Toy)

ATH · Post by **ATH** » Sat Jun 23, 2012 2:31 pm

Please tell what intercooler you used - Dastek

where did you get the pipes - SAC

What chip did you use with it - SAC

who did this work for you - SAC

jacques kotze · Post by **jacques kotze** » Sun Jun 24, 2012 9:39 am

SAC did my intercooler & chip. Had a few problems but they sorted it out

OOOOMS · Post by **OOOOMS** » Sun Jun 24, 2012 10:09 am

Chris, what size intercooler are you planning on fitting?

Front mount / top mount?

ChrisF · Post by **ChrisF** » Sun Jun 24, 2012 12:07 pm

Mark if I go through with this, it would probably be a front mount unit. Just cant see myself cutting up the bonnet.

whe stuck behind a truck doing 100km/h I want the intercooler and chip ... the rest of the time I think of reliability and resale value ...

BUT, this is a long term vehicle so maybe the resale issue is not really an issue ....

OOOOMS · Post by **OOOOMS** » Sun Jun 24, 2012 7:03 pm

If you can get a top mount 3.0 D4D intercooler it would de first prize, cut the hole and don't be a sissy man!

Fitting a front mount entails a lot more tubing and you have to cut through the wall in front of your battery anyway.....and the silicone pipe is expensive......

Traveler · Post by **Traveler** » Sun Jun 24, 2012 8:14 pm

Looked at this, you can fit without cutting the bulkhead. You can use stainless piping and can get away with much less silicone piping. The silicone piping is the weak link in the setup.

OOOOMS · Post by **OOOOMS** » Sun Jun 24, 2012 8:21 pm

Traveler wrote:Looked at this, you can fit without cutting the bulkhead. You can use stainless piping and can get away with much less silicone piping. The silicone piping is the weak link in the setup.

Agree, I had to replace some of mine as it had chafed through. Did not replace some of it with stainless, but two sections with mild steel from an exhaust place down the road for R100.

Traveler · Post by **Traveler** » Mon Jun 25, 2012 6:50 am

This is where I am procuring my project components from.
http://www.mrturbo.co.za/index.php?opti ... 1&Itemid=1" onclick="window.open(this.href);return false;

ATH · Post by **ATH** » Tue Jun 26, 2012 7:46 am

I studied this for a while (being a non-tecchie) and then took it in to SAC.

The first go was the chip and intercooler and Dyno results showed an increase from 68.2 to 81kw and 238 to 286Nm. Unfortunately the Dyno pointed out that the thermostat was a bit ill so rebooked for this solution and re-dyno. unfortunately needed to do some mileage but got back to SAC and had things sorted. Now 87.9kw and 301Nm torque.

Whilst these figures don't match the phamplet specs I am quite happy. The Lux is much better and has a new lease on life at 200000km.

Whilst the thermostat was said to be responsible for a slightly higher fuel consumption, I look forward to a long run with all fixed. However, I do think that my consumption will increase because you just have to use the extra legs on the Lux. The change of thermostat took the figures from 80.7 to the final 97.9Kw and torque from 287Nm to the final 301Nm.

Some interesting points and perhaps those in the know can comment:
- figures achieved and those advertised by SAC were said to be different as a result of altitude and barometric pressure etc. Is this fact or BS?
- fitting a snorkel to increase cool air ... SAC reckon that the snorkel has a smaller air flow passage than no snorkel and reduces performance. I can understand this to a point but have also read that the snorkel sorts out the pesky turbo lag.
- is it better to get the Lux dyno'd in JHB for better results?

Look forward to comments - it's a great forum!

ATH · Post by **ATH** » Tue Jun 26, 2012 7:51 am

Sorry, I am wishing ... last post should read a final Kw of 87.9

OOOOMS · Post by **OOOOMS** » Tue Jun 26, 2012 9:29 am

Some interesting points and perhaps those in the know can comment:
- figures achieved and those advertised by SAC were said to be different as a result of altitude and barometric pressure etc. Is this fact or BS? I would think you would get better performance with the turbo down at the coast.......?
- fitting a snorkel to increase cool air ... SAC reckon that the snorkel has a smaller air flow passage than no snorkel and reduces performance. I can understand this to a point but have also read that the snorkel sorts out the pesky turbo lag. Air-flo to the filter is definitely more as referred to ram air effect, I noticed the difference when I fitted mine.
- is it better to get the Lux dyno'd in JHB for better results? I recently had mine remapped / dyno'd after 18 months of original installation and can feel the difference, feels like a new van!

Traveler · Post by **Traveler** » Tue Jun 26, 2012 10:09 am

Andre, if you see the size of the air intake standard on the Hilux vs. Snorkel you will know that the person at SAC making that comment was just winging it. I am surprised by your small increase in performance with chip and intercooler. Toyota get 100kw out the Fortuner in 2.5D4D

With the snorkel you also get a slight ram air effect because you are forcing air into the snorkel as you are driving; you cannot get that with a normal dyno.

Yes, as you increase in altitude and air density decrease the power delivery does decrease.

Get the Dyno done in the area where you use the vehicle the most.

ATH · Post by **ATH** » Tue Jun 26, 2012 10:47 pm

OOOOMS and Traveller, seem to think that either I have a general performance problem on the Hilux or that there are some interesting issues at hand regards the fitment and chip. Assuming that intercooler is okay (dastek and all) can the issue be that the SAC chip is not as good as a Dastek chip? Can it be that SAC have not set it up correctly?

When driving up to JHB, I notice a drop in power and when calling SAC regards this (same source as the snorkel info) I am told that between the coast and reef you can expect an 18% drop in power. Any ideas on which way I should run with this?

OOOOMS · Post by **OOOOMS** » Tue Jun 26, 2012 11:06 pm

ATH wrote:OOOOMS and Traveller, seem to think that either I have a general performance problem on the Hilux or that there are some interesting issues at hand regards the fitment and chip. Assuming that intercooler is okay (dastek and all) can the issue be that the SAC chip is not as good as a Dastek chip? Can it be that SAC have not set it up correctly?

When driving up to JHB, I notice a drop in power and when calling SAC regards this (same source as the snorkel info) I am told that between the coast and reef you can expect an 18% drop in power. Any ideas on which way I should run with this?

When last did you have it Dyno'd? When mine was done I got 99.6kw and that was without the intercooler.
Could be that the setup is not done properly or ther could be something els wrong. The first time when I had the chip fitted, the Dastek tech called me and told me that my actuator on the turbo was cracked, I had it relpaced (found one at some turbo place, fitted it and took it back) they dyno'd it again for free and happy as a pot-belly-pig. Look, the 2.5 is no race car, let's make that clear :!:

Traveler · Post by **Traveler** » Wed Jun 27, 2012 6:46 am

PS. The SAC Chip is generally always a Dastek chip.

Yes, you can expect 15-20% drop in power between GP and the coast. However with a Turbo vehicle that drop is always on the lower side as the Turbo forces air into the engine.

Quintin · Post by **Quintin** » Wed Jun 27, 2012 4:47 pm

mmm lekker om te droom eendag sal ek ook 500HP of meer wil he:)

ATH · Post by **ATH** » Fri Jun 29, 2012 5:21 am

Hi Guys,
Thanks for all of the feedback ... I am taking the matter up with SAC and am better informed to do this thanks to your info.

ATH · Post by **ATH** » Sun Jul 01, 2012 5:50 pm

After a long chat with SAC it seems that the 28% increase in power is good. They will re-dyno the vehicle and map out the best fuel efficiency for normal driving and keep the power.

Regards the Kw variation, apparently each ane every dyno is different and no two dynos will give the same readings. I am none the wiser.

I will keep this thread updated on the outcome.

ATH · Post by **ATH** » Thu Jul 19, 2012 6:15 pm

Just got back from SAC and much better performance. 90.2kW and 312Nm. Part of the issue was that the original carpet under the pedal was only allowing 70% throttle. Sorted out and much better response and the fuel efficiency was tuned in better.

OOOOMS · Post by **OOOOMS** » Thu Jul 19, 2012 6:17 pm

ATH wrote:Just got back from SAC and much better performance. 90.2kW and 312Nm. Part of the issue was that the original carpet under the pedal was only allowing 70% throttle. Sorted out and much better response and the fuel efficiency was tuned in better.

ATH · Post by **ATH** » Thu Jul 19, 2012 6:33 pm

The BS baffles ...

but it is better than the original spec. i am sure that if I cut a piece off the roofliner I will find some kW too!

OOOOMS · Post by **OOOOMS** » Thu Jul 19, 2012 6:37 pm

ATH wrote:The BS baffles ... but it is better than the original spec. i am sure that if I cut a piece off the roofliner I will find some kW too!

Just go on a diet......

ATH · Post by **ATH** » Thu Jul 19, 2012 6:56 pm

Good one!

damazon · Post by **damazon** » Mon Jul 23, 2012 1:34 pm

I had SAC (Dastek) chip fitted about 18 months ago and kw went up to 92 from 74.

I had SAC free flow exhuast fitted last week and kw went up to 102, but what was great was torque figures, up from 220/1500 rpm to 280/1500 rpm. Very very little lag!! like a new truck.

I did a trip to Durban from Jhb and with the extra power, hills are not a problem and the legs are much longer. However I did the trip record time, and only because I could!! It was so much easier. Consumption suffered though, 65 liters for 585kms.

Fitting intercooler soon, will give an update.

ATH · Post by **ATH** » Mon Jul 23, 2012 4:31 pm

Dave, sounds good! Look forward to seeing the figures with the intercooler.

OOOOMS · Post by **OOOOMS** » Mon Jul 23, 2012 5:06 pm

Have a look at the bend behind the turbo......

Then compare with these pics

That is a problem...... :wink2:

OOOOMS · Post by **OOOOMS** » Mon Jul 23, 2012 5:07 pm

OOOOMS wrote:Have a look at the bend behind the standard 2.5 turbo......

Then compare with these pics

IMG00653-20120625-1747.jpg

IMG00654-20120625-1747.jpg
That is a problem...... :wink2:

The bend.....

ChrisF · Post by **ChrisF** » Mon Jul 23, 2012 7:31 pm

and the solution is ??? before this question drives me around the bend ....

Traveler · Post by **Traveler** » Mon Jul 23, 2012 7:57 pm

The solution is in the pictures Mark posted.

The Toyota 90Deg sharp angle they fit causes swirling.

damazon · Post by **damazon** » Tue Aug 21, 2012 10:27 am

Ok had the intercooler fitted,!!
Stats as follow:
chip fitted: 99.6Kw @3500rpm, 283.2Nm @2500rpm
exhaust fitted: 104.4Kw @3500rpm, 294.7Nm @2000 rpm
Intercooler: 116.5Kw @3500rpm, 355.2 @2000rpm

Not in 3.0L territory but close!

Have just arrived in Lusaka after a trip through Botswana and Zimbabwe. My consumption is up a little, however I think its due to the speeds I can travel now

the truck pulls well and cruises great in 5th. 4th gear its like a mule, endless power it seems!! The mix is great, decreasing lag well(not eliminating) and has a great mid range power band. Great for overtaking. Im happy!!

OOOOMS · Post by **OOOOMS** » Tue Aug 21, 2012 2:14 pm

damazon wrote:Ok had the intercooler fitted,!!
Stats as follow:
chip fitted: 99.6Kw @3500rpm, 283.2Nm @2500rpm
exhaust fitted: 104.4Kw @3500rpm, 294.7Nm @2000 rpm
Intercooler: 116.5Kw @3500rpm, 355.2 @2000rpm

Not in 3.0L territory but close!

Have just arrived in Lusaka after a trip through Botswana and Zimbabwe. My consumption is up a little, however I think its due to the speeds I can travel now the truck pulls well and cruises great in 5th. 4th gear its like a mule, endless power it seems!! The mix is great, decreasing lag well(not eliminating) and has a great mid range power band. Great for overtaking. Im happy!!

Wow!!! Stats look impressive

What size intercooler did you fit?

Traveler · Post by **Traveler** » Tue Aug 21, 2012 2:16 pm

Dave, you got excellent results. The torque jump has been impressive.

ChrisF · Post by **ChrisF** » Tue Aug 21, 2012 3:33 pm

Mark I never got feedback from the intercooler add on the other forum ...

Mr_B · Post by **Mr_B** » Tue Aug 21, 2012 3:52 pm

Traveler wrote:Dave, you got excellent results. The torque jump has been impressive.

Minor mods and it's already so much more powerful than a Nissan whats-its-name...

OOOOMS · Post by **OOOOMS** » Tue Aug 21, 2012 3:56 pm

ChrisF wrote:Mark I never got feedback from the intercooler add on the other forum ...

Happens often......

Traveler · Post by **Traveler** » Tue Aug 21, 2012 3:58 pm

Mr_B wrote:
Traveler wrote:Dave, you got excellent results. The torque jump has been impressive.
Minor mods and it's already so much more powerful than a Nissan whats-its-name...

A Micra?

Chris, you might want to consider MrTurbo for an intercooler. http://www.mrturbo.co.za/index.php" onclick="window.open(this.href);return false;

ChrisF · Post by **ChrisF** » Tue Aug 21, 2012 5:05 pm

Thanks Heinrich, maybe later.

Mark forwarded me a link of a good deal in the Cape. Contacted the gent, said I am in the Cape and would like to come over ..... never replied ......

Due to my camera addiction I dont have the money for this conversion now. AND, the bakkie has about 6 months of the factorie warrantee left ..... but then ..... :)

Traveler · Post by **Traveler** » Tue Aug 21, 2012 8:35 pm

Of all the options their prices were best.

ATH · Post by **ATH** » Tue Aug 21, 2012 10:27 pm

No 2.5 can go untouched ........

Traveler · Post by **Traveler** » Wed Aug 22, 2012 5:48 am

ATH wrote:No 2.5 can go untouched ........

"Built, not bought"

ATH · Post by **ATH** » Wed Aug 22, 2012 6:06 am

damazon · Post by **damazon** » Wed Aug 22, 2012 8:40 am

@ Mark, I"m not sure what size intercooler it is bud! Its the one from SAC!

As pointed out, once you start tinkering with the 2.5 the bug bites and you cant stop!!

but its all good

OOOOMS · Post by **OOOOMS** » Wed Aug 22, 2012 9:33 am

damazon wrote:@ Mark, I"m not sure what size intercooler it is bud! Its the one from SAC!

As pointed out, once you start tinkering with the 2.5 the bug bites and you cant stop!! but its all good

Tx Dave

Just curious.....

When you have a spare moment could you please measure it L x W x H

damazon · Post by **damazon** » Wed Aug 22, 2012 10:41 am

sure thing, I will measure

ChrisF · Post by **ChrisF** » Wed Aug 22, 2012 1:05 pm

Dave while you are at it ... PLEASE take a LOT of pics .... :)

damazon · Post by **damazon** » Sun Aug 26, 2012 3:05 pm

Hi Guys

Sorry for delay in reply, just got back last night late from Lusaka via Harare.

Blanche, my van pulled like a train, very sweet!!

Anyway, I treated her to a nice pamper, full house wash!! I swear she smiled at me!!

@Mark, difficult to measure exact but in the region of about 550mm x 250mm x 75mm. I didnt have a tape measure so it is definite guestimate. I will do it properly in time, sorry!

@Chris, some pics for you

damazon · Post by **damazon** » Sun Aug 26, 2012 3:08 pm

Dont know what happened to the pics, try again