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  • 90 Series Front Mount Intercooler

    Hey all, I was looking at installing a front mount intercooler on my 2002 KZJ95R. I got in touch with a few shops and can’t seem to find anyone who will make one up specifically for the 90 series. There are kits for the 120 1KZ but the battery/airbox configuration is opposite and also a kit for the 1KZ hilux. Just wondering if anyone had bought one of these and just had a go at making it work and how you went? Also if anyone was keen from WA I spoke to Performance Diesel Intercoolers in Perth today and they said if someone was willing to drop their car off for 3 days for them to take some measurements they’d consider putting a kit together for it. Being in Qld it’s a bit out of the way for me…

    Thanks in advance!

  • #2
    Lots of work if you want to retain aircon etc.
    Everything is on the wrong sides but can be shifted, the petrol’s air box is on the RHS, guess that idea depends if you already have a snorkel!
    Most owners give up and just fit a thermo fan to the top mount.

    Comment


    • #3
      So I’m realising the more I look at it… but I am getting some inspiration looking at the HPD front mount intercooler for the 1KZ hilux which has the air box and battery on the same side as the 90 series (link below).

      https://hpdiesel.com.au/products/int...ux-1kz-te.html

      Their kit sits a bit lower than I would like (right behind the bullbar?) and I’m considering putting the intercooler right behind the front grill in front of the air con hoses. I am hoping with a bit of fancy pipe work I can make it happen?

      This is the intercooler I was considering:

      https://www.ebay.com.au/itm/FMIC-Uni...154756-20017-0

      From what I can work out this should fit in the space I’m looking at and is roughly the same capacity as the intercooler on there but right up the front in the breeze. I might knock up a box or a block of hard foam or something with the same dimensions to give me an idea.

      Use something like the below for pipework:

      https://www.ebay.com.au/itm/UNIVERSA...154756-20017-0


      OR work out the exact bends and lengths I need and get a shop to make them up for me.

      As much as I’d like a purpose made kit etc and not using eBay parts, surely the engine would be happier with the cooler air?

      Comment


      • #4
        Originally posted by postmandean View Post
        So I’m realising the more I look at it… but I am getting some inspiration looking at the HPD front mount intercooler for the 1KZ hilux which has the air box and battery on the same side as the 90 series (link below).

        https://hpdiesel.com.au/products/int...ux-1kz-te.html

        Their kit sits a bit lower than I would like (right behind the bullbar?) and I’m considering putting the intercooler right behind the front grill in front of the air con hoses. I am hoping with a bit of fancy pipe work I can make it happen?

        This is the intercooler I was considering:

        https://www.ebay.com.au/itm/FMIC-Uni...154756-20017-0

        From what I can work out this should fit in the space I’m looking at and is roughly the same capacity as the intercooler on there but right up the front in the breeze. I might knock up a box or a block of hard foam or something with the same dimensions to give me an idea.

        Use something like the below for pipework:

        https://www.ebay.com.au/itm/UNIVERSA...154756-20017-0


        OR work out the exact bends and lengths I need and get a shop to make them up for me.

        As much as I’d like a purpose made kit etc and not using eBay parts, surely the engine would be happier with the cooler air?
        Hey mate, from my understanding, I reckon with these custom install jobs you're best to just calculate what straight pieces and silicon bends you need and make it yourself. I've recently bought some silicon bends pretty cheap off this Aussie Ebay seller: https://www.ebay.com.au/usr/oscarjz who has been awesome to deal with. Calculate what pipe you need. I was creating a custom stainless steel snorkel with silicon bends and went to AAA Exhaust in Adelaide to get the staight pipe as it was an unusual diametre (2.75") and my usual steel supply joint didn't stock it.

        I've looked at doing a front mount in my 2000 Prado 1kz-te and theres no way i could see it working without removing the air con compressor radiator or plumbing under the coolant radiator and compressor radiator. There simply didnt look like there was enough room to fit the pipe work around the outside. Easily anyways.

        For comparison, i'm running 16psi boost from a CCP high flow turbo, 3 " PPD exhaust, 3 bar map sensor, 2.75" SS snorkel into stock air filter box, brand new standard (oem spec) radiator, new water pump + 71 deg thermostat, top mount stock intercooler with a cheap Hilux style bonnet scoop. Everything is running tip top with no overheating issues and performance compared to stock standard is pretty impressive. (I'm still chasing more though :P ). I do wonder if the whole front mounted intercooler thing is a VERY minimal gain vs effort and cost.
        Last edited by SamSta; 02-06-2022, 10:31 PM.

        Comment


        • #5
          Hey thanks for the reply! 16psi boost sounds great!! That was the other alternative right was to put on a hilux bonnet scoop!

          I’ve got a PPD exhaust in a cart online, do you rate it?

          I was going to try to mount it right behind the front grill and dive down to go through the steel body work under the battery and try to come up around the intake of the turbo. Some fairly dramatic s-bends and a fair distance but I can’t help but love the idea especially when ambient temps are near freezing in Winter. I’m probably more chasing the cooler running temps more so than the “performance” side of things. I’ll definitely be looking up the other parts you mentioned as well though like the turbo etc. Thanks again for the reply!

          Comment


          • #6
            Hey mate, sorry I missed your reply there. Just revisiting this now as my top mount has a bloody hole in it and I need to replace. How did you get on in the end? You sounded pretty keen to make the front mount work.

            I think Carco is right. Top mount with fan is the way to go with this car. The space around the engine and radiator is just too tight for all the pipework. I actually think maximum airflow to your radiator should be priority. I've removed my spot lights from the front and repositioned the number plate to ensure maximum flow to the radiator. And my 95 series purrs along even when the engine is up to temp so not sure how much the intercooler heat soak thing is a problem. Maybe my bonnet scoop is actually doing something! Haha I took my fan out because I foolishly installed it last time without rubber mounts and it eventually rubbed through the aluminum cores on the radiator from all the engine vibration. So there's a lesson for everyone! I've also heard the fan doesn't do a great deal so might not even be worth having on there.

            Anyways, keen to hear your updates

            Comment

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