Front-mount Cirrus intercooler fitment on KZTE
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Front-mount Cirrus intercooler fitment on KZTE
So I finally installed the intercooler on mu 'Lux. Now remember that mine is a pre-facelift model, and this kit is NOT a straight fit on this specific model.
Here is a brief description of how I did it. This is NOT an instruction on how to do it, so if you break your Hilux or make a big hole in your hand - don't come blame me
OK - first up you need a Hilux KZTE - looks something like this:
Next up you are going to need the Cirrus intercooler - looks like so when you unpack the box:
Now in the box you'll also find a piece of paper that they call "Instructions" - these give you some pretty good pointers.
You will start off by removing the front bumper and grille) (This is kind of hard to do if you have a bullbar that is not removed yet ). Be patient when removing the grille otherwise you're going to break clips and things.
Next up you must start sizing the intercooler up and how you are going to fit it. While I was trying to fasten the cooler with the rubber mountings that come with the kit, they broke - not very tough things. So I made my own plan using some suspension rubbers I had lying around in the garage.
Remove the standard boost pipe between the turbo and the throttle, also remove the 4 bolts from the throttle that hold the boost pipe in place.Remember to unbolt the boost sensor from the pipe as well. Take the first boost pipe from the kit and fasten it to the turbo's outlet.
Now here comes a part you won't enjoy - you have to make a hole on either side of the intercooler for the boost pipes to go through to the engine bay. Now in the instructions they suggest using a 76mm holesaw and make two holes and tadaaa... Ja whatever. A Hilux will not be mutilated that easily. You will have to use a jigsaw or the likes. I used a jigsaw to make these holes. After making them just touch up the bare metal with some paint to prevent corrosion before placing the rubber shielding on it. Feed the second boost pipe through and connect it to the intercooler. Use one of the supplied connectors to join it to pipe 1 - you may need to cut it a bit shorter. Feed pipe no 3 through the hole on the passenger side of the cooler and fasten it to the cooler with a hose clamp.
Use a small bit of silicon sealant and apply it to both sides of the spacer that goes onto the throttle. Place the metal boost pipe onto this and fasten with the supplied bolts. Fasten the fourth boost pipe onto the metal boost pipe, and connect it to the third boost pipe using a connector.
(Sorry for the lack of pictures up to here - was too busy looking for my sense of humour to take pictures at this stage )
It should now look more or less like this:
Like I said earlier - this kit is actually designed for the facelift model. I had to modify my front bumper to make it all fit (Not particularly happy about having to do so....)
This is how mine looks now:
After re-painting the bullbar and re-fitting the spotlights
In terms of results, I am rather impressed. Even though I have not fiited a chip yet, I can feel a very real difference. I used to feel the boost started at around 2100rpm and lasted to about 2800rpm. Now it starts boosting at around 1900rpm and boosts past 3000rpm. Response is much better and it feels like I have to give less throttle input in every day driving.
Here is a brief description of how I did it. This is NOT an instruction on how to do it, so if you break your Hilux or make a big hole in your hand - don't come blame me
OK - first up you need a Hilux KZTE - looks something like this:
Next up you are going to need the Cirrus intercooler - looks like so when you unpack the box:
Now in the box you'll also find a piece of paper that they call "Instructions" - these give you some pretty good pointers.
You will start off by removing the front bumper and grille) (This is kind of hard to do if you have a bullbar that is not removed yet ). Be patient when removing the grille otherwise you're going to break clips and things.
Next up you must start sizing the intercooler up and how you are going to fit it. While I was trying to fasten the cooler with the rubber mountings that come with the kit, they broke - not very tough things. So I made my own plan using some suspension rubbers I had lying around in the garage.
Remove the standard boost pipe between the turbo and the throttle, also remove the 4 bolts from the throttle that hold the boost pipe in place.Remember to unbolt the boost sensor from the pipe as well. Take the first boost pipe from the kit and fasten it to the turbo's outlet.
Now here comes a part you won't enjoy - you have to make a hole on either side of the intercooler for the boost pipes to go through to the engine bay. Now in the instructions they suggest using a 76mm holesaw and make two holes and tadaaa... Ja whatever. A Hilux will not be mutilated that easily. You will have to use a jigsaw or the likes. I used a jigsaw to make these holes. After making them just touch up the bare metal with some paint to prevent corrosion before placing the rubber shielding on it. Feed the second boost pipe through and connect it to the intercooler. Use one of the supplied connectors to join it to pipe 1 - you may need to cut it a bit shorter. Feed pipe no 3 through the hole on the passenger side of the cooler and fasten it to the cooler with a hose clamp.
Use a small bit of silicon sealant and apply it to both sides of the spacer that goes onto the throttle. Place the metal boost pipe onto this and fasten with the supplied bolts. Fasten the fourth boost pipe onto the metal boost pipe, and connect it to the third boost pipe using a connector.
(Sorry for the lack of pictures up to here - was too busy looking for my sense of humour to take pictures at this stage )
It should now look more or less like this:
Like I said earlier - this kit is actually designed for the facelift model. I had to modify my front bumper to make it all fit (Not particularly happy about having to do so....)
This is how mine looks now:
After re-painting the bullbar and re-fitting the spotlights
In terms of results, I am rather impressed. Even though I have not fiited a chip yet, I can feel a very real difference. I used to feel the boost started at around 2100rpm and lasted to about 2800rpm. Now it starts boosting at around 1900rpm and boosts past 3000rpm. Response is much better and it feels like I have to give less throttle input in every day driving.
Nothing is impossible - it just costs more
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Re: Front-mount Cirrus intercooler fitment on KZTE
Nice job, keep us informed of the improvements re: power and consumption. Any pictures of the pipes in the e-bay
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Re: Front-mount Cirrus intercooler fitment on KZTE
Very nicely done.
Where did you get the kit, and how much did it cost ?
Where did you get the kit, and how much did it cost ?
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Re: Front-mount Cirrus intercooler fitment on KZTE
Bought it from Cirrus Coolers ( http://www.cirruscoolers.com" onclick="window.open(this.href);return false; ) at R3900
Will take some pics of the pipes in the week
Will take some pics of the pipes in the week
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Re: Front-mount Cirrus intercooler fitment on KZTE
Nice job,can you feel a difference in power?
Hilux=Masjien
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Re: Front-mount Cirrus intercooler fitment on KZTE
I'd say there is an increase in overall power, but the big gain is the power spread. It is much more driveable now and the turbo is spooled much earlier
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Re: Front-mount Cirrus intercooler fitment on KZTE
Andre
So jy se daar is minder turbo lag? Dis baie goeie nuus!
Baie geluk goeie artikel!
So jy se daar is minder turbo lag? Dis baie goeie nuus!
Baie geluk goeie artikel!
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Re: Front-mount Cirrus intercooler fitment on KZTE
Baie beslis beter! Hy ry nou sommer baie lekkerder
Ek het Sondag opgevul net nadat ek alles klaargemaak het. Sondag na Pretoria gery, my vrou het vandag dorp toe gegaan, ons seun gaan oplaai by die skool, ek is vanaand aksie-krieket toe. Op pad terug huiswaarts vanaand toe maak ek gou weer vol want my nuuskierigheid het die beter van my gekry...
Nou die beste wat ek ooit gekry het tot dusver was 9.1km/l. Ek kry gewoonlik so 8.9km/l. Vanaand se opvul was 25.1l na 248km - 9.88km/l!
Baie bly om dit te sien, veral as jy in ag neem dat ek eintlik bietjie harder gery het as gewoonlik - hy trek dan soooo lekker
Ek het Sondag opgevul net nadat ek alles klaargemaak het. Sondag na Pretoria gery, my vrou het vandag dorp toe gegaan, ons seun gaan oplaai by die skool, ek is vanaand aksie-krieket toe. Op pad terug huiswaarts vanaand toe maak ek gou weer vol want my nuuskierigheid het die beter van my gekry...
Nou die beste wat ek ooit gekry het tot dusver was 9.1km/l. Ek kry gewoonlik so 8.9km/l. Vanaand se opvul was 25.1l na 248km - 9.88km/l!
Baie bly om dit te sien, veral as jy in ag neem dat ek eintlik bietjie harder gery het as gewoonlik - hy trek dan soooo lekker
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Re: Front-mount Cirrus intercooler fitment on KZTE
Andre,
Dis fantasties, so ou kan reken op so 11% verbetering op brandstof verbruik.
Het jy n chip ingesit?
Sou n ou een moet insit? Voor en nadele van net intercooler sonder n chip?
Dis fantasties, so ou kan reken op so 11% verbetering op brandstof verbruik.
Het jy n chip ingesit?
Sou n ou een moet insit? Voor en nadele van net intercooler sonder n chip?
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Re: Front-mount Cirrus intercooler fitment on KZTE
I have a KZ-TE that tends to run warmer than I would like it to do when driving uphill, fully loaded at (110km/h).
Will a fitment like this make my engin run cooler? By how much?
Will a fitment like this make my engin run cooler? By how much?
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Re: Front-mount Cirrus intercooler fitment on KZTE
Ek het nog nie een ingesit nie, maar ek sal vroeg in Februarie een laat insit. Die man van Cirrus reken dit is nie krities om een in te sit nie, maar dit is wanneer jy werklik volle voordeel sal trek uit die intercooler. Ek glo dit sal egter beter en veiliger wees om die chip in te sit en seker te maak die mengsels is regHilux01 wrote:Andre,
Dis fantasties, so ou kan reken op so 11% verbetering op brandstof verbruik.
Het jy n chip ingesit?
Sou n ou een moet insit? Voor en nadele van net intercooler sonder n chip?
Nothing is impossible - it just costs more
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Re: Front-mount Cirrus intercooler fitment on KZTE
Andre
As jy se "volle voordeel" is dit in performance of koeler enjin?
Ek nie gepla oor performance nie, wil net my masjien koeler laat loop as hy hardwerk
As jy se "volle voordeel" is dit in performance of koeler enjin?
Ek nie gepla oor performance nie, wil net my masjien koeler laat loop as hy hardwerk
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Re: Front-mount Cirrus intercooler fitment on KZTE
Nee, Henk - ek weet nie of dit jou probleem sal oplos nie... Ek het nog geen temperatuur probleme met myne gehad nie
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Re: Front-mount Cirrus intercooler fitment on KZTE
Henk, in theory, the intercooler should help reduce the temp due to the lower temp of the incoming air.
The intercooler also gives a better combustion due to the air been denser meaning less strain on the motor, so depending on how hot your vehicle is running it could solve some of your problem.
Dodging Very nice work, hope you enjoy it.
The intercooler also gives a better combustion due to the air been denser meaning less strain on the motor, so depending on how hot your vehicle is running it could solve some of your problem.
Dodging Very nice work, hope you enjoy it.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Apparently an intercooler does not help for a cooler running engine, the opposite happens. Due to the air entering the engine being cooler, it is has a higher density and therefor burns better and hotter...
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Re: Front-mount Cirrus intercooler fitment on KZTE
that is why you should retune your engine adding more fuel.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Henk, an intercooler will have no effect on your water temp. It may actually make it worse if you fit it in front of the radiator due to resricting the airflow.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Steve, that is the one question no one want or can answer for me to date. How much will you restrict the airflow with? I also understand that the size of the IC ….will play a role. Is it by 2%, 5% 10% or is it a non-issue. Most IC vehicles have front mounts and they seem to be doing OK or have I been misinformed? This question is not aimed at discrediting the restriction of airflow theory. If you think logically it will but I am sure that someone must have done the math’s around the restriction – I could just not find someone that could give me the “scientific proof” for that question. Anyone here that can plszepplin wrote:It may actually make it worse if you fit it in front of the radiator due to resricting the airflow.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Hi Andre
Neat job I must say now that I saw it over the w/end. Did you really have to cut the bumper? What do you think would/would not have hapened if you did not? Just a thought, otherwise I like.
Regards
Neat job I must say now that I saw it over the w/end. Did you really have to cut the bumper? What do you think would/would not have hapened if you did not? Just a thought, otherwise I like.
Regards
Tumelo Maketekete
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Re: Front-mount Cirrus intercooler fitment on KZTE
Howzit Thumelo!
Without cutting the bumper on our models, you won't be able to fit it back on with the cooler in place. You basically need to cut off the middle two mounting points on the steel half of the bumper (The plastic bumper bolts onto these points), and then cut the grille section of the bottom half out. If you don't cut the mounting points they'll cut into the cooler and cause damage
Without cutting the bumper on our models, you won't be able to fit it back on with the cooler in place. You basically need to cut off the middle two mounting points on the steel half of the bumper (The plastic bumper bolts onto these points), and then cut the grille section of the bottom half out. If you don't cut the mounting points they'll cut into the cooler and cause damage
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Re: Front-mount Cirrus intercooler fitment on KZTE
Hi Andre
Is jy met daai nuwe intercooler deur die water by Groenkloof ,of het jy ook die water gedodge soos ek?
Is jy met daai nuwe intercooler deur die water by Groenkloof ,of het jy ook die water gedodge soos ek?
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Re: Front-mount Cirrus intercooler fitment on KZTE
Hulle se hy's n 'heavy-duty' cooler, so....
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Re: Front-mount Cirrus intercooler fitment on KZTE
Neil, I have not seen any scientific data to support this theory but just my sense of logic at work here. Probably only a tiny amount which will not even register on the dash guage. Same applies to the air flow already being fractionally heated up by the IC thus will be warmer through the radiator.
Shoot me down guys
Shoot me down guys
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Re: Front-mount Cirrus intercooler fitment on KZTE
Baie mooi Andre-Geniet jou nuwe intercoolerDodging wrote:Hulle se hy's n 'heavy-duty' cooler, so....
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Re: Front-mount Cirrus intercooler fitment on KZTE
Ya oom Dawie, jy se jy die water gewat?
Tumelo Maketekete
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We don't stop playing because we grow old, but we grow old because we stop playing!
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Re: Front-mount Cirrus intercooler fitment on KZTE
Julle kan ook na my thread kyk (viewtopic.php?f=3&t=16162&p=187006#p187006" onclick="window.open(this.href);return false;) wat Werner van Headzone se kommentaar is oor 'n intercooler (en hy sê nie 'n intercooler is 'n slegte idee nie, maar jy moet jou EGT dophou). Dit klink asof hy weet waarvan hy praat.
Andre, jy gee my hoop as ek sien hoe diep jy in die water ingaan. Dink net as jy 'n snorkel het. Dan kan jy die water tot net bokant jou deurhandvatsel laat kom, en hande was, as die water skoon is
Andre, jy gee my hoop as ek sien hoe diep jy in die water ingaan. Dink net as jy 'n snorkel het. Dan kan jy die water tot net bokant jou deurhandvatsel laat kom, en hande was, as die water skoon is
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Re: Front-mount Cirrus intercooler fitment on KZTE
Donkey,Ek het maar die water ge "bypass".Maybe next time.Do not want to do watercrossings without diff breather extentions.Donkey wrote:Ya oom Dawie, jy se jy die water gewat?
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Re: Front-mount Cirrus intercooler fitment on KZTE
Ag ek laaik my vrou sommer kwaai - more vat sy ons bakkie na SAC toe vir n chip
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Re: Front-mount Cirrus intercooler fitment on KZTE
Andre, dan gaan jy eers 'n verskil ervaar. Gaan heerlik loop saam die intercooler.
As jy die meeste uit die setup wil kry moet jy net 'n snorkel bysit sodat jy nog meer lug kan intrek as deur die standaard Toyota strooitjie
As jy die meeste uit die setup wil kry moet jy net 'n snorkel bysit sodat jy nog meer lug kan intrek as deur die standaard Toyota strooitjie
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Re: Front-mount Cirrus intercooler fitment on KZTE
I'm not much of diesel fundi... but is it not better to mount the IC on top of the engine with a scoop on the bonnet... I can imagine that after a few muddy water crossing the IC radiator could get clogged, leading to heavily reduced efficiency?? I know the alu radiator fins are not that hard and bend pretty easy when cleaned with a high pressure cleaner...
Just my thoughts?
Just my thoughts?
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Re: Front-mount Cirrus intercooler fitment on KZTE
I note that all the new Toyota D4D's have the IC installed on top of the engine... with the bonnet scoop! Maybe this is because there is no longer enough space up front, with all the other radiators in place... how would fitting an aftermarket bumper affect this type of installation??
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Re: Front-mount Cirrus intercooler fitment on KZTE
There are 2 schools of thought on that one Bretton.
With the IC on top, when crawling in 1L there is little to no air forced into the bonnet scoop. and warm enginebay air rising from below, which also negates any cooling advantage. This can be overcome by fitting cooling fans and water nozzles to keep the IC cooled.
In front there are no engine heat rising through the IC, and the IC is also more exposed to the little bit of air movement that is present even at that low speed. What you say about mud is true and also makes sense. So once again, both configurations have pro's and cons...
With the IC on top, when crawling in 1L there is little to no air forced into the bonnet scoop. and warm enginebay air rising from below, which also negates any cooling advantage. This can be overcome by fitting cooling fans and water nozzles to keep the IC cooled.
In front there are no engine heat rising through the IC, and the IC is also more exposed to the little bit of air movement that is present even at that low speed. What you say about mud is true and also makes sense. So once again, both configurations have pro's and cons...
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Re: Front-mount Cirrus intercooler fitment on KZTE
Hey Mr. B
This specific intercooler is flippin' tough. When you actually see it in front of you, you'll realise how rugged it is. I have a 1700w pressure washer and it does nothing to the cooler except clean it.
This specific intercooler is flippin' tough. When you actually see it in front of you, you'll realise how rugged it is. I have a 1700w pressure washer and it does nothing to the cooler except clean it.
Nothing is impossible - it just costs more
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Re: Front-mount Cirrus intercooler fitment on KZTE
Cool Andre, I was just curious, I've got no experience with forced induction engines... Thys, if the IC is top mounted, is it not possible to put a pull through fan below the IC? Guess space will again be an issue...
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Re: Front-mount Cirrus intercooler fitment on KZTE
Yes Bretton, it is possible to fit cooling fans, and misting nozzles etc, but as you say space becomes a problem. Nothing is impossible with careful planning though.
Thys de Jager
CEO and Refreshments Manager at Team Offroad.
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email: thys@teamoffroad.co.za
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1997 Jeep Wrangler TJ 4.0 Sport. The original SFA. AGA... Gooi kole
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Re: Front-mount Cirrus intercooler fitment on KZTE
Oh yes - this cooler won't fit with an aftermarket bumper, unless the bumper gets made specifically for the application. The cooler will be rather exposed though...
Nothing is impossible - it just costs more
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Re: Front-mount Cirrus intercooler fitment on KZTE
OK, chip's done
Before - 88kw & 271nm
After - 103kw & 345nm
These are just the numbers my wife gave me - I'll check out what correction factors they used on the dyno. In my experience SAC likes to give you some krismis-figures on the gains.
My wife says the van really does pull nicely though. Can't wait to test it tonight
Before - 88kw & 271nm
After - 103kw & 345nm
These are just the numbers my wife gave me - I'll check out what correction factors they used on the dyno. In my experience SAC likes to give you some krismis-figures on the gains.
My wife says the van really does pull nicely though. Can't wait to test it tonight
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Re: Front-mount Cirrus intercooler fitment on KZTE
Job well done Andre. Dalk wys om een van daai nette voor te sit vir al die goggas.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Ja ek het van daai mesh opgesit om die groter ggg's uit te hou - hulle was moeilik uit
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Re: Front-mount Cirrus intercooler fitment on KZTE
My wife rolled with my kz-te a few years back before I could fit the IC from SAC. Now I drive the D4D but I am so tempted to want to know how much better that IC you have fitted makes the engine perform during summer dry seasons. Used to drive to Zambia a lot as well as Kariba and I would feel the loss of power when I reached 110km/hr. Ever tried top speed driving?
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Re: Front-mount Cirrus intercooler fitment on KZTE
Never gave it a top speed run...
This weekend we went out to Ohrigstad. Vehicle was carrying a rather heavy load, 4 people, A/C on all the way and kept it at a true 120km/h. Got 9.8km/l - happy with that. Overall acceleration has improved, no need to change down for even steep uphills, good overtaking ability.
Happy with the end result
This weekend we went out to Ohrigstad. Vehicle was carrying a rather heavy load, 4 people, A/C on all the way and kept it at a true 120km/h. Got 9.8km/l - happy with that. Overall acceleration has improved, no need to change down for even steep uphills, good overtaking ability.
Happy with the end result
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Re: Front-mount Cirrus intercooler fitment on KZTE
My Kz has done over 200 000km with the intercooler on and never ran out of steam. Can sit at 120-140km/h all day and not even break a sweat.nematombo wrote:My wife rolled with my kz-te a few years back before I could fit the IC from SAC. Now I drive the D4D but I am so tempted to want to know how much better that IC you have fitted makes the engine perform during summer dry seasons. Used to drive to Zambia a lot as well as Kariba and I would feel the loss of power when I reached 110km/hr. Ever tried top speed driving?
Once I had to move really fast in an emergency and saw 171km/h on the GPS - and there was room for more!
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If you aren't raising your hand, raise your standards!
A 4x4 is merely a machine that enables you to get stuck further away from civilization.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Dodging wrote:Bought it from Cirrus Coolers ( http://www.cirruscoolers.com" onclick="window.open(this.href);return false; ) at R3900
Will take some pics of the pipes in the week
Hello Dodging, ek het ook 'n Cirrus intercooler gekoop en ek sukkel so biekie met die pype tussen the inlaat en air cleaner. Kan jy dalk vir my so n paar foto's neem van joune asb.
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Re: Front-mount Cirrus intercooler fitment on KZTE
Razor wrote:Dodging wrote:Bought it from Cirrus Coolers ( http://www.cirruscoolers.com" onclick="window.open(this.href);return false; ) at R3900
Will take some pics of the pipes in the week
Hello Dodging, ek het ook 'n Cirrus intercooler gekoop en ek sukkel so biekie met die pype tussen the inlaat en air cleaner. Kan jy dalk vir my so n paar foto's neem van joune asb.
Probleem opgelos, so dis noe nodig vir die foto's nie :-)
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Re: Front-mount Cirrus intercooler fitment on KZTE
Bly om te hoor - ek't nou eers gesien
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Re: Front-mount Cirrus intercooler fitment on KZTE
Ek het my van na http://www.tuneserv.co.za/" onclick="window.open(this.href);return false; gevat lasweek om 'n unichip te laat installeer.
Ek moet se my van hardloop nou laat die biesies bewe
Waar ek normaalweg moes n rat terug gaan om teen die bulte uit te kom hou ek nou in 5de en tel spoed op teen die bulte.
Vandag het ek 'n Osram H4 HID Xenon kit geinstalleer en dit het n groot verskil gemaak.
Die lang nweek is ek in die Drakensberg en dan sal ek sien hoe die ligte werk wanneer ons in die aande gaan ront ry in die berge.
Ek moet se my van hardloop nou laat die biesies bewe
Waar ek normaalweg moes n rat terug gaan om teen die bulte uit te kom hou ek nou in 5de en tel spoed op teen die bulte.
Vandag het ek 'n Osram H4 HID Xenon kit geinstalleer en dit het n groot verskil gemaak.
Die lang nweek is ek in die Drakensberg en dan sal ek sien hoe die ligte werk wanneer ons in die aande gaan ront ry in die berge.