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  • Fitted an intercooler and bonnet scoop

    My UK model Prado didn't come with an intercooler, so I decided to finally fit the Prado intercooler that I bought 2 or 3 years ago... Because I have a bullbar, spots, airhorn, etc. in the way of the grill scoops, I also fitted a Hilux bonnet scoop. I can't believe what a difference the intercooler is making.

    I did make some other changes too though... I re-located the Econokit hoses and reactor to take the bends out of the hoses which should in theory make it more efficient and deliver more water. This required some drilling and trimming of the exhaust manifold heat shield. The yellow tubing is just some flexible heat shield to give the silicone hose a bit more protection where it is touching the shield.



    And I removed the throttle body butterfly. The biggest challenge on the 1KZ-TE is getting more air through it, so the throttle butterfly just seems a pointless restriction to me - its only fully open at full throttle and I never drive full throttle. At all part throttles it is just limiting the amount of air going into the motor. With the butterfly removed it does make a very small judder on shutdown, but only I notice it really. In case anyone wants to do this too, be aware that the little screws holding it in, are flattened on the ends so that they cannot be screwed out - they need to be drilled out (make sure you catch all the filings/swarf). I didn't get any pics of this.

    The intercooler install wasn't all straight forward. At first I was going to fit the proper intake manifold that is intended for the intercooled 1KZ-TE, but after seeing where the throttle wheel and throttle position sensors sit on the new manifold, I decided that the easier option is to make a throttle body to intercooler adapter plate and throttle cable mounting bracket. My first version of the adapter plate was very clever and positioned the tube part of the adaptor perfectly vertical (the face of the throttle body slopes in toward the engine). What I had not accounted for in this version was the non-intercooled manifold is actually almost an inch wider than the intercooled version. So this happened...



    So I had to modify the adapter to have the tube part come out perpendicular to the flange, and then use flexible silicone hose to make the small bend. As I couldn't find a 20 degree bend I tried to modify a 45 degree bend, but that didn't really work so well and I ended up using a straight piece of 2.5" silicone hose.



    Because of the 1" body lift I also bought a longer piece of 2.5" hose to go on the turbo side, except when it came time to fit it I found out that it is 2" hose on that side... Doh! So I used the std hose to make 2 inner sleeves so that I could use the bigger diameter hose. It seems to be holding up, but this will be replaced with a decent 2" hose asap.

    The throttle cable guide was mounted to the standard intake pipe, so I made a small bracket that bolts onto the intake manifold.



    Cutting the bonnet took much longer than I thought it would. I bought a proper Hilux scoop because I liked that it came with mounting tabs, and isn't just sikaflex'd on. It took a bit of trial and error to get the hole in the right place, and in the right shape (la fat T shape), rather cutting too little and then taking a bit more off where needed. I first drilled 4 1" holes with a hole saw and then tried to cut the straight lines with a reciprocating saw. This didn't go too well as the saw is a bit of a hand full when cutting something with too much flex in it like a bonnet - it kept grabbing the metal. I managed not to scratch the bonnet with it, but after just one cut swapped it for the grinder with a thin metal cutting disc. I would have preferred to use the jigsaw (like I did with the snorkel), but the blade wouldn't be long enough with the double skinned bonnet and would probably not have worked. I managed to position it so that I could still use the standard rubber bonnet seal.



    The scoop has 8 mounting points, but for some reason the 3 front points protrude beneath the mounting surface of the scoop, so it lifted the front of the scoop leaving a 10mm gap at the front. In the end I cut the front tabs off and fixed it with a small cap head screw in the front. When it is all painted I will fit a black cap head so that it won't be as noticeable.





    To help the airflow into the scoop I fitted an 8" fan onto the intercooler grill. There is a small gap between the intercooler and the grill which should be enough for the fan to create a high pressure area so that the air goes through the whole intercooler and not just around the outside where the fan blades are.

    I then made a temporary shroud in true McGuyver fashion with some McGuyver tape. Without the shroud I could feel that some of the air was coming back up, rather than through the intercooler. I will replace this with a more permanent shroud asap.



    The power for the fan is sourced from the wiper motor as it only comes on with the ignition fully on. This live wire is then run to a relay via a 50C normally open thermo switch, so that the fan only comes on when the intercooler gets over 50 degrees. This is so that the fan doesn't always run when I need to have the ignition on without the car running for some reason, although for the life of me I can't think when I would have the ignition on for long enough that it would matter. But I did it anyway in case it ever happens... The thermo switch is just cable tied to the intercooler intake pipe.



    Job done (this pic was before I fitted the little mounting screw in front).



    All that is left now is to have the scoop (and probably bonnet) painted, and I need to tidy up all the new wiring.

    Best of all, there were hardly any bolts left over...

    95 3.0 Camp Car, 150 V6 Daily Driver[SIZE=4]
    [/SIZE]

  • #2
    Well done mate. Nice job! I'll be keen to see how you do the shroud. It would be interesting to know what your new power and torque figures are after a tune.
    Interesting to see you got more than 4 pics in the one post. I wonder if that is a recent forum upgrade thing?
    Cheers, Ben.

    Comment


    • #3
      I assume you have complied as necessary - Page 8

      http://pan.search.qld.gov.au/search/...ection=qld-gov

      Comment


      • #4
        Originally posted by Torrie 72 View Post
        Well done mate. Nice job! I'll be keen to see how you do the shroud. It would be interesting to know what your new power and torque figures are after a tune.
        Interesting to see you got more than 4 pics in the one post. I wonder if that is a recent forum upgrade thing?
        Cheers, Ben.
        I'm also quite curious to see what a difference a new dyno tune will make - I just need to remember where I left that $400... I think the next job will be painting the bonnet though. At the moment I'm trying to decide whether this is something that I should have a crack at myself - I've only sprayed hub caps before, and one is flaking a little bit...

        For the shroud I will probably keep it simple and use a piece of rubber mat to cover the masked off area.

        Originally posted by JoshF View Post
        I assume you have complied as necessary - Page 8

        http://pan.search.qld.gov.au/search/...ection=qld-gov
        I've had a read through that and I think that I am OK - the intercooler is only bringing it up to locally approved specification and I don't think I exceed the 20% power increase limit anyway (I wish!), and my bonnet scoop would need to be roughly 5x as tall before it becomes a problem
        95 3.0 Camp Car, 150 V6 Daily Driver[SIZE=4]
        [/SIZE]

        Comment


        • #5
          so I am naughty for posting the QLD compliance regs which was a very negative thing to do it seems...I am sorry to all for bringing down the tone and hopefully no defect notices are ever issued

          Comment

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