200tdi intercooler opinion

[D90user]

I'm mid swap on putting a defender 200tdi (thanks Tony) in my series 1. Motor is mounted and now I'm dealing with fitting all the bits in. Lots of small fitment issues....

Would running a 200tdi without a intercooler be a bad idea, even if I detuned it a bit?

What about longevity? If I make sure the EGT's stay good will there be there be any down side except a power loss?

I can make the stock radiator and engine driven fan fit if I dont run an intercooler (or run a small one). But with an intercooler it is really tight, and I would have to run a small electric fan. My thoughts on detuning are that I really dont need the full power of the 200, it will pull that little truck fine, and a little less power woudl be good on the transmission. It is an 86" soft top with a high ratio transfercase.

I'm trying to keep it as stock looking as possible from the outside, so no moving of the breakfast. thanks..

[KevinNY]

I'd think with a little creative tube routing you could mount an IC in front of the radiator. I have a Saab IC between my grill and radiator in my Series III with the radiator in the usual spot.

[D90user]

I have been looking at the saab intercoolers, and I can do that if I dont use the engine driven fan.
I think I can use a 300tdi intercooler if I go electric.
Are you running an electric fan?

But the simplicity of the fan clutch if appealing.

[mikeslandrover]

The Land Rover turbo diesel engine didn't last long and that didn't run an intercooler:(
I'd try and get one in somehow. surely there's space between the grill and the radiator.:confused

[meatblanket]

But the simplicity of the fan clutch if appealing.

You're stuffing a 200tdi in an 86 and you want simplicity?:)

I'd very much like to see some pictures of what you have going on, since I might try to do the same thing at some point in the future. I'm running a 2.5 NA in my 86 now, and I found that there isn't an abundance of room in there to run an engine driven fan. I'm sure it could be done, but I'm using an electric pusher on mine.

One problem seems to be that if you push the radiator too far forward to make room for a puller fan, you end up with it interfering with the front crossmember and the steering relay. But the intercooler is smaller and could probably fit in over top of the front crossmember and between the radiator and the grill.

It seems most logical to put the intercooler in front, hang a relatively thin but efficient aluminum radiator behind that, and then use a high cfm but low clearance Spal puller fan.

Figuring out all the plumbing will be fun!

[D90user]

After a few hours of measuring, I think this might fit between the headlights up against the grill:
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?VISuperSize&item=170538328840

It will be close but I think I'll be able to keep the engine driven fan. Piping will be a pain, but no too bad.

I'm going to switch to power steering as the steering box barely fowls on the turbo. Could maybe shim it but....

I'll post some pictures.

[KevinNY]

I can't get your ebay link to open. I have just enough room for the engine fan but run an electric puller fan now, noticeable difference in power believe it or not.

[D90user]

try this:
http://cgi.ebay.com/ebaymotors/Turbo-Intercooler-Front-Mount-18x12x3-PRELUDE-Saab-EVO-_W0QQcmdZViewItemQQhashZitem27b4e06308QQitemZ17053 8328840QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccesso ries

[KevinNY]

That would certainly be more than adequate.

[mikeslandrover]

That's about twice the size of the standard one. Tyre smokin:)

------ Follow up post added March 19th, 2011 08:43 AM ------

My thoughts on detuning are that I really dont need the full power of the 200, it will pull that little truck fine, and a little less power woudl be good on the transmission. It is an 86" soft top with a high ratio transfercase.

I'm trying to keep it as stock looking as possible from the outside, so no moving of the breakfast. thanks..

I ran a series transmission behind a Rover 3.5 V8 for years with no problems, Torque out puts are similar but with much lower revs from the tdi.
A friend ran a disco tdi in a series 2 with 3.54:1 diffs for a long while just fine, it was a little rocket.:)

[kevkon]

I have toyed with the idea of replacing my 2.25 with a diesel. I sometimes wonder if a front mounted intercooler is really the best option in this application.

[UnfrozenCaveman]

Silly boy ... http://www.lrsoc.com/forum/index.php?topic=7181.msg48601#msg48601

[D90user]

Silly boy ... http://www.lrsoc.com/forum/index.php?topic=7181.msg48601#msg48601

I am an avid lurker on LRSOC.... but a LHD swap has a few issues that RHD does not, this being one, the steering being the other. That is a great forum

------ Follow up post added March 19th, 2011 12:36 PM ------

I sometimes wonder if a front mounted intercooler is really the best option in this application.
?? I'm all ears...

[UnfrozenCaveman]

Oh rats, I forgot you were LHD.

Sorry.

KAA

I am an avid lurker on LRSOC.... but a LHD swap has a few issues that RHD does not, this being one, the steering being the other.

[D90user]

No worries... If I did not know about LRSOC I would be dead in the water!

[kevkon]

Well, some car makers and race cars locate the intercooler in the fender area (smic) or even on top of the engine (tmic). Of course, these locations require proper ducting and even fans to work effciently. But there are options besides the front.

[ajh]

Another option though it probably goes against everything a Series owner believes in; is an air to water unit pulled out of another vehicle. Then they can be mounted just about anywhere though the less air pipe the better.

[D90user]

no pride here.
I looked at the air to water intercoolers but the addition of another waterpump made me stop looking.

I just pulled the 300tdi inter cooler out and it looks like it may be easier to fit.

any thoughts on these?
http://www.siliconeintakes.com/product_info.php?cPath=19&products_id=223&osCsid=100dfbaaca27aa4e2e890ca24716ca7d

completely useless?

[kevkon]

Personally that looks like it would just take up space and collect heat from the proximity to the engine/exhaust. Not to mention that it looks like a good dirt collector.

[Macker]

It's not the most ideal setup, but here's what I currently have on my lhd 200tdi series. It fits in the cut-out pretty well. The truck currently has the original non power steering box. Here's where I mounted my intercooler, off a defender I think. I made some custom intercooler tubing with a couple 90° bends on each side to connect it. The pipes do have to go between the engine and the radiator (original series). So there are a few extra bends and I would bet there's a small amount of heat soak from the radiator at idle and slow speeds, but I think it's better than not running an intercooler at all.

[mgreenspan]

If you're doing this install you might have already stumbled across this but if not here it is. http://www.glencoyne.co.uk/200di2.htm http://www.glencoyne.co.uk/200di.htm

Since you're already talking about detuning this might be a better option for you. Richard's done a load of these conversion and 200tdi conversion in 90s and 110s, is very knowledgeable and would probably answer any emails you send his way.

[mikeslandrover]

If you're doing this install you might have already stumbled across this but if not here it is. http://www.glencoyne.co.uk/200di2.htm http://www.glencoyne.co.uk/200di.htm

Very informative web site. :thumbs

[D90user]

I have been using some of his info... great website. thanks for the heads up though.

I'm not sure I'm ready to get rid of the turbo completely...I like the idea of having a series 1 with loads of torque.
I'm going to cram a decent sized intercooler in, it is just easy to get lazy mid project.

I still may de-tune it a tad, to try to bump up the mpg and keep the odds of breaking the lay shaft down.

[130Tdi]

sad when you have to de-tune a 107hp engine. this is going to be cool Steve. btw hows the camper coming along ?

[D90user]

Ha.. you are so right.
Camper is... kicking ass and taking names. These are some pics from Mexico in January. It is working better than expected. Very livable and lighter than before. I should start a build thread here and actually update it, this is the only forum I really like.

I think the S1 is going to be sweet too but thanks for the kind words... it can be tuff to see the light at the end of the tunnel. Tony (16kpsi) has helped out a lot with getting the engine settled... it is a tight fit. Last pic is one at the submarine factory:cool:

[mikeslandrover]

I'm sure the transmission will cope with the 107bhp from the tdi. A friend built a s11 with a dicso 200tdi and it was fine and very fast due to lightness.
The camper looks awesome how's it constructed? 110 chassis with a series 2/3 ambulance body?
Interested to hear/see more about the build.:)

[cgalpin]

Submarine factory... I think I've found my dream garage. Mmmh

Steve, please do make a build thread for both!

[130Tdi]

Submarine factory... I think I've found my dream garage. Mmmh

Steve, please do make a build thread for both!

Yeah-hence Tony's screen name 16kpsi.

[JSBriggs]

The camper looks awesome how's it constructed? 110 chassis with a series 2/3 ambulance body?
Interested to hear/see more about the build.:)

http://www.d-90.com/forum/showthread.php?t=25852

Steve is one of those 'lifestyle' types. He takes 'living in a van down by the river' to a whole new level. :grin

-Jeff

[mikeslandrover]

http://www.d-90.com/forum/showthread.php?t=25852

Steve is one of those 'lifestyle' types. He takes 'living in a van down by the river' to a whole new level. :grin

-Jeff

Does that thread need moving to build-ups and restores?

[cgalpin]

I can make that happen if Steve wants it to be.

[D90user]

I can make that happen if Steve wants it to be.
that would be great!

[cgalpin]

Done!