Intercoolers

Improved Power and Torque

The power and torque increase delivered by fitting a 4WD Systems Intercooler Kit to a turbocharged diesel 4WD vehicle is substantial. The engine generates greater output due to the gains in efficiency derived from the reduced ambient temperature of the induced air and increased airflow. The reduced temperature allows the use of higher fuel load and boost pressure settings for achieving even greater output.

Increasing both turbocharger boost pressure and fuel input increases combustion temperature, hence energy output of the engine. Ultimately the maximum output of the engine is limited by combustion temperature. An Intercooler is fitted between the turbocharger outlet and the engine intake manifold to reduce intake air temperature. This allows the setting of higher boost and fuel loads but retain moderate combustion temperatures, required for engine longevity.

The graphs below (click to enlarge) display the obvious advantages of turbocharging and intercooling the normally aspirated engine.

Power	Torque

Landcruiser 100 Series, 1998 GXL, 1HZ manual, 275.70.16 tyres, 2.5" Mandrel Exhaust, 12lbs boost

4WD Systems has 2 alternative Intercooler Kits:

The 'Glycol to Air' Intercooler has the advantage of improved thermodynamic efficiency due to the liquid-air heat exchange. Its close proximity to the intake manifold means there is no opportunity for reheating of the compressed air or reducing airflow and its performance is not related to vehicle speed. Another advantage is an easy install as only 19mm heater hose is used (to transport the glycol to its own radiator), rather than 65-75mm or greater air hose.
Expect a maximum of 17% extra torque.

The 'Air to Air' Intercooler comes with a comprehensive DIY kit and is quite simple to fit. They are a 'Front Mount' style so there is almost no transfer of heat from the engine to the intercooler core - a common problem with the 'Top Mount Air to Air' style.
Similar heat reductions are achieved to the Glycol-Air' kits over approximately 70km/hr.
Cost effective price for very similar torque gains.

Complete with detailed instructions for DIY fit. Significant improvements can also be gained from fitting a Snorkel, Hiclone, Unifilter foam aircleaner element and upgraded injector settings.

Intercoolers