06 Hilux turbo intercooler

[jjacelon1]

Anyone installed an aftermarket inter-cooler on a 2006-2009, 2.5 Hilux yet ?
Thinking of doing it but was looking for feedback before trying d project.

[jjacelon1]

I installed d front mount intercooler.

After installation, lost 1lb. of boost along the distance (9lbs. before & 8lbs. after). Simple 1/8" spacers between the waste-gate and where its mounted - returned boost
back to 9lbs.

The intention was never to achieve a super-fast diesel. It was simply to have a more constant boost level & make it easier on the engine during the hotter times of the day.

06 Hilux - 2.5 L, 4x4
intercooler - 2" x 6" x 14"
Piping lines - 2" OD
Silicone elbows & couplings
Minor body mod (for pipes to pass thru radiator wall)
Four 1/16" washers (2 a side, as waste-gate spacers).
Wheels/tires - 31" x 10.5" x 15"


Result:
Intercooler @ 8lbs boost - 1lb less is enough to feel sluggish but is constant
throughout the day. Burns a bit more fuel at a faster rate.

Intercooler @ 9lbs. boost - feels more powerful and responsive on acceleration (even when already moving, don't need to gear down to overtake like before). Fuel consumption similar to pre-intercooler. Engine seems to "labor" a lot less during hottest time of day (11am to 2pm).

Don't plan to raise boost higher than the stock 9lbs, as I'm not sure how much it can be raised to safely. All in all I'm pleased with the result as is.

Any one know safe max. boost allowable ?

[Stuckindmud]

nice .. throw up some pics !

[gundelero]

pics....

[smokin-anger]

i raised mine to 15lbs buh make sure and install a pyrometer first!! so far it pulls great, still to install an intercooler lookin for the right specs on one i hav a hilux 4x2 2.4L

[V2NR 3.0]

throw up some pics...

[Team Loco]

pics or we say you lie

[V2NR 3.0]

I installed d front mount intercooler.

After installation, lost 1lb. of boost along the distance (9lbs. before & 8lbs. after). Simple 1/8" spacers between the waste-gate and where its mounted - returned boost
back to 9lbs.

The intention was never to achieve a super-fast diesel. It was simply to have a more constant boost level & make it easier on the engine during the hotter times of the day.

06 Hilux - 2.5 L, 4x4
intercooler - 2" x 6" x 14"
Piping lines - 2" OD
Silicone elbows & couplings
Minor body mod (for pipes to pass thru radiator wall)
Four 1/16" washers (2 a side, as waste-gate spacers).
Wheels/tires - 31" x 10.5" x 15" i have stock, so i should feel the power more

Result:
Intercooler @ 8lbs boost - 1lb less is enough to feel sluggish but is constant
throughout the day. Burns a bit more fuel at a faster rate.

Intercooler @ 9lbs. boost - feels more powerful and responsive on acceleration (even when already moving, don't need to gear down to overtake like before). Fuel consumption similar to pre-intercooler. Engine seems to "labor" a lot less during hottest time of day (11am to 2pm).

Don't plan to raise boost higher than the stock 9lbs, as I'm not sure how much it can be raised to safely. All in all I'm pleased with the result as is.

Any one know safe max. boost allowable ?

I am particularly interested in your update jjacelon1 because i have an after market inter-cooler of almost similar specs to install as well. What now has me a little concerned is highlighted in red above. Any feedback with pics you can give is appreciated.

[PTME]

i hav 1 installed but started to lose power and accelaration so i jus disconnected it. However after reading bout raising the boost i'm considering doing it, so if u cAN HOOK ME UP WIT ur mechanic or jus tell me wat u did i;ll be appreciative.

[PTME]

i hav 1 installed but started to lose power and accelaration so i jus disconnected it. However after reading bout raising the boost i'm considering doing it, so if u cAN HOOK ME UP WIT ur mechanic or jus tell me wat u did i;ll be appreciative.

[V2NR 3.0]

pics pics

[bluespeed]

anyone has a stock intercooler to sell from a diesel pickup in good condition?

[Stuckindmud]

I thought this fella was supposed to put up pics of this install..

shenanigan!

[jjacelon1]

finally got some time time to take & post the pics...sorry git took so long guys.

[jjacelon1]

intercooler top

[jjacelon1]

waste gate

[jjacelon1]

Intercooler piping

[lighthammer]

^^ ok now ur talking...
See was that soooooo hard?


Nice job there meng.
Did you dyno the hilux yet?

[V2NR 3.0]

Looks nice. Can we get a frontal view of the IC ?.

Im still deliberating given the boost lost

[Stuckindmud]

Thanks man , nice job , did you do the install yourself?

Does the 2kd have an exhaust gas recirculation line to the intake?

[jjacelon1]

^^ ok now ur talking...
See was that soooooo hard?


Nice job there meng.
Did you dyno the hilux yet?

Thanks man.
Didn't get to dyno as yet.

[jjacelon1]

Thanks man , nice job , did you do the install yourself?

Does the 2kd have an exhaust gas recirculation line to the intake?

Thanks man.
Yup, did the install myself.
No, the 2kd doesn't have a blow-off recirculation line from the turbo to the intake but I'm definitely planning on putting in one soon.

[jjacelon1]

Looks nice. Can we get a frontal view of the IC ?.

Im still deliberating given the boost lost

Will have to take a frontal pic of the IC to post. I thought I had one.

Hey man, the lost boost was regained with 1/8"spacers...
I don't think you you get any simpler/cheaper than that. (no boost controller added)

[Silvermike]

jj... where u got the piping kit done?

also, y 2" and not 2.5"?

[Stuckindmud]

Sweet, btw -no need for the BOV - its a diesel - it doesnt need it.

When you raised the boost back , did it affect the diesel milage?

[jjacelon1]

jj... where u got the piping kit done?

also, y 2" and not 2.5"?

Did it myself. A freind had the equipment, I had the material, concept & time.

2" because - Standard diesel sized piping for stock calibration.
Based on the air volume moved by the stock turbo, distance from turbo to intake and intercooler size (inlet/outlet/core), a 2.5" piping kit would have created a greater lag and make the turbo work harder to achieve the required boost psi.
Size was actually calculated via a formula that I got online and reviewing other vehicles with similar vehicle specs/piping run/engine size/intercooler/etc.

Hey, if it ain't broke...don't fix it.

[jjacelon1]

Sweet, btw -no need for the BOV - its a diesel - it doesnt need it.

When you raised the boost back , did it affect the diesel milage?

I know it doesn't need it...but it would reduce the stress on the turbine and increase the efficiency. Seems worth it to me for the piece of mind.

Fuel/mileage returned to stock values after raising back the boost. So, same basic fuel consumption with better response and less engine effort.

[Silvermike]

thx for the reply... i looked it up myself and i came to the same conclusion... it also help with laminar flow at the low air velocities. which is where a diesel operate as it doesn't really go past 5k rpm.

i wanna run about 12psi on my ranger, but i wanna upgrade the fmic before i try. so im looking into making a kit like this of my own soon.

[jjacelon1]

thx for the reply... i looked it up myself and i came to the same conclusion... it also help with laminar flow at the low air velocities. which is where a diesel operate as it doesn't really go past 5k rpm.

i wanna run about 12psi on my ranger, but i wanna upgrade the fmic before i try. so im looking into making a kit like this of my own soon.

You mean stream-line flow ("Leminar flow" refers to liquid movement in parallel layers, with no disruption between the layers)...but I get what u mean and you are right.

I could be wrong but I believe that the Ranger & BT50 come with the PSI factory set at about 11/13 psi. Check it b4 you spend your $$$.
Let me know how the kit turns out.
Just remember at the end of the day we have diesel vehicles running on poor quality diesel. We could improve the performance a bit... but only so much.

[jjacelon1]

Here are the frontal pics of the IC.