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The Front Mounted Intercooler install

This is the regular top mount intercooler on an Isuzu 3.1.

Bigger is better, and this location makes maintenance a pain.

Shiny blingy intercooler.

Quite cheap from eBay

Comparing the old and the new.

Not only is the new one twice the size,  but its also a lot thicker.

 

Early stages of installation.

Large holes had to be cut through the front panel, to allow the hoses through.

The battery had to be moved, as did the expansion tank.

Even a dent was needed in the air-cleaner housing for clearance.

With the bumper and grille off, the size of the intercooler can clearly be seen
This is about as neat as its possible to get the piping without custom bends.

I've heard of people modifing the inlet manifold to make the pipe runs easier, but this has led to some cylinders running lean.

The EGT valves have been removed completely

 

A boost gauge is plumbed into the inlet manifold to measure the boost.

It was a fitting tapped into the inlet manifold, forward of the main inlet.

 

The gauge itself is an industrial liguid filled gauge, and is only fitted when I'm changing things.

A bleed valve is installed between the wastegate and the turbo. This introduces a "leak" into the system, and encourages the system to make more boost.
Even with the bleed valve wide open, I'm only getting 11psi. I was hoping for more like 15-16psi.

So the next stage is to shorten the waste-gate rod, by screwing it in several turns. But this is very tricky to do with the turbo in place, unless you are left handed.

A lot of people want to add an intercooler, to their 2.8 Isuzu's

Here is a picture of a UK spec 2.8 Trooper.

As you can see the inlet manifold is radically different.

It is possible to swap on a 3.1 manifold, and even a top mount intercooler.

© Andrew Marshallsay 2008