mondy TD front intercooler conversion

[PercyBigun]

heres the pics of it all done. i have ordered a blue pipe to replace the ugly orange one on the top, then it will look loads better. its a renault 21 turbo intercooler and a RS turbo crossover pipe over the top of the engine. then a few samco and cossy hose bends, and 2 lengths of 50mm diam. shiney steel pipe.











and this is where the standard intercooler position is, the most stupid place possible. it was doing no good up there and now with the new position the dump valve sounds much louder and more crisp. plus now the car drives much better and gives a much bigger kick when the turbo kicks in.

click for pic

[Sharon]

Re: mondy TD front intercooler conversion

I dont think you will get anything else under there

Looks a clean car

[FF_Mark]

Re: mondy TD front intercooler conversion

Looks good, but how do you get on putting oil in it ?

[PercyBigun]

Re: mondy TD front intercooler conversion

i need to get an angle grinder and cut off that flange on the crossover pipe. unfrotunately the crossover has to go there cos its the only position the bonnet will close.

[ZetecVan]

Re: mondy TD front intercooler conversion

Mate that looks well rude. cud do wiv a rs500 cooler but i doubt it'll fit like!

Like da cam cover well tasty

Chris

[PercyBigun]

Re: mondy TD front intercooler conversion

its about the size of a I/C on a TDCi 130 so it cant be too bad. does the job fine for now, i dont need anything bigger until i get a upraded turbo. then i can put a saab 9000 I/C in there (fits no probs cos i aint got aircon)

[dangerousdave]

Re: mondy TD front intercooler conversion

What kind of power is this at now percy and what did it start as? I got my gay as 70hp td escort and im tempted to make it a beast...mine dont even have the intercooler think that alone puts 20hp on as thats what the 90hp engine has (maybe bigger turbo too?!??)

[ZetecVan]

Re: mondy TD front intercooler conversion

Nah mate i was only jokin about da 500 cooler! So what power u kickin out an how did ya get your dump valve to work on a diesel

[PercyBigun]

Re: mondy TD front intercooler conversion

no idea what power mine is at now but a while ago when i got the fuelling and boost wound up that mod adds 25-30bhp and a shite load of torque to the 1.8TD which is 89bhp as standard. it really made a massive difference you could feel (not like sticking on a performance air filter where you cant feel anything) and this intercooler jobby has now added another nice hike in power (its also got a whacking cone filter and powerflow zorst system now aswell).

unfortunately i got a big loss in power/acceleration when i went from 17" to 18" alloys, not only cos of larger rolling radius but the 18s i have got weigh a ton. plus i have a massively heavy boot install and non-standard leather interior which weighs more than it should. stripped out and on small wheels this baby could really kick arse!

the dump valve works with a microswitch on the throttle mechanism, a solenoid and some pipework. quite simple really!

[dangerousdave]

Re: mondy TD front intercooler conversion

Hmmm may have to have a little play with my escort on the cheap then, was thinkin of raiding a pease pottage td for its intercooler and all flow meters etc as thats the only differences for 20bhp! Then again i should be doing my harrier

[PercyBigun]

Re: mondy TD front intercooler conversion

have you got a photo of your turbo and behind the cam cover (near exhaust manifold) and i can tell you how easy or hard it will be to whack a intercooler on there.

your best bet might be to find a mondeo 1.8TD in a scrappy and get the turbo and exhaust manifold off it. then its just a case of doing the same pipework and intercooler that i did. or you could stick the rubbish ford intercooler on the top. and nick the MAF off it while your there!

some big power gains are to be had for not alot of money and fairly simple work.

[dangerousdave]

Re: mondy TD front intercooler conversion

Hmm sounds like a plan il get some pics when its light and isnt raining! As for the td, mine is broke i think as it doesnt want to come on boost until right up in the revs ie will cut in at 25mph in 1st but then hits the rev limiter at 30mph and i can feel the turbo fluttering in and out when im in 5th at about 80mph...any ideas where to start as your the resident td tuner

[FF_Mark]

Re: mondy TD front intercooler conversion

Is this the same motor they put in the last Escort Van TD , I wonder what BHP they were.

[dangerousdave]

Re: mondy TD front intercooler conversion

Id guess so if its turbod? Mine says endura-d on the cam cover. If it is the same the non intercooled ones are 70bhp and the intercooled ones are 90bhp...then the tdci's in focus's are 110 i think, and the latest best one is 130bhp....not bad for a diesel

[PercyBigun]

Re: mondy TD front intercooler conversion

yeah but the latest TDCI 130 actually dynoes at 143bhp as standard, i now know 3 mondeos who have had it dynoed at that. add a unichip to one of those and they gain 35bhp! then they will piss all over a St24 2.5V6 petrol mondy.

yes mine is endura-de engine aswell but the older mk1 mondeo 1.8TD which looks identical and just says "1.8 DIESEL" on the cam cover - you can nick the turbo, intercooler and exhaust manifold off one of them aswell. in fact the mk1 mondy TD has a bigger turbo, they fitted smaller one on the mk2 for less lag.

as i said if you post close up pics of that area of your engine i can advise if you can just whack an intercooler on, or if you need the turbo and manifold etc aswell.