ZD30 intercooler

[Oddie1969]

Hi all. Just wondering if someone could tell me how hard it is to change the intercooler on a 2006 3.0lt. I’ve misplaced my Haynes manual so I’m just wondering if it’s just remove and replace of is there more involved than that ?

Thanks in advance :thumbup:
Graham

[mudski]

Should take less than a stubbie to remove and refit. Two hose clamps, unclip a sensor and four bolts....

[Oddie1969]

Should take less than a stubbie to remove and refit. Two hose clamps, unclip a sensor and four bolts....

Right, that sounds like something even I might be able to manage, thanks 👍

[Mc4by]

I don't know a screwdriver from a spanner and I got it done on my own.
I did leave a blanking bolt out but got that sorted quickly :)

[Oddie1969]

I don't know a screwdriver from a spanner and I got it done on my own.
I did leave a blanking bolt out but got that sorted quickly :)

Ha ha. 🤣 Mine is leaking a lot of oil so I wasn’t sure if there were oil lines that needed to be considered, after a bit more reading it looks like that may be coming though with the air.

[BillsGU]

When you say "fitting a new one" are you talking original or aftermarket? Some of the aftermarket ones (like the one I purchased years ago) are a pain to fit. Most Patrol owners these days get the original IC modified by getting the core removed and a more efficient core TIG welded in its place. This gives you better cooling of air plus it wont leak AND it is guaranteed to fit.

[10G]

Ha ha. 🤣 Mine is leaking a lot of oil so I wasn’t sure if there were oil lines that needed to be considered, after a bit more reading it looks like that may be coming though with the air.

Yep, do you have a catch can fitted?

I live in the "don't know a screwdriver from a spanner" drawer as well plus I specialise in forgetting things, but the oil will be coming from your PCV blowing back into your air inlet. The catch can goes a fair way towards removing that oil. Please someone correct me if I'm wrong.

There's not meant to be oil in the IC, just wind.

[threedogs]

easy enough to change once the engine cover is removed.
Not sure on prices but a change over IC fully tigged will
be approx 33% bigger

[Oddie1969]

When you say "fitting a new one" are you talking original or aftermarket? Some of the aftermarket ones (like the one I purchased years ago) are a pain to fit. Most Patrol owners these days get the original IC modified by getting the core removed and a more efficient core TIG welded in its place. This gives you better cooling of air plus it wont leak AND it is guaranteed to fit.

Aftermarket direct swap. Welded instead of crimped but all the same dimensions. All done, went in like a dream.

[Oddie1969]

Yep, do you have a catch can fitted?

I live in the "don't know a screwdriver from a spanner" drawer as well plus I specialise in forgetting things, but the oil will be coming from your PCV blowing back into your air inlet. The catch can goes a fair way towards removing that oil. Please someone correct me if I'm wrong.

There's not meant to be oil in the IC, just wind.

Ha ha, we sound like twins ! :biggrin:

No I don’t have a catch can, I was reading about those, are they worth it ? Do I need to be cleaning anything else so the intercooler doesn’t get clogged up again ?

[Oddie1969]

easy enough to change once the engine cover is removed.
Not sure on prices but a change ove IC fully tigged will
be approx 33% bigger

Yes it was easy. I paid $466 in Perth, I know there are some cheaper but they seem to be all sold out. I didn't want one of the +$1000 ones as we are planning to upgrade the car soon. I didn’t actually measure it but it appears to be the same size.

[threedogs]

Yes it was easy. I paid $466 in Perth, I know there are some cheaper but they seem to be all sold out. I didn't want one of the +$1000 ones as we are planning to upgrade the car soon. I didn’t actually measure it but it appears to be the same size.

You need to remember its only a 3ltr it will only go sooo fast.
making it more efficient would be a better goal imo
Sounds like you got a great deal.

[pollenface]

You should definately fit a catch can, and not a cheapy from ebay because they don't have a baffle and are essentially useless. Also I don't think you really want a "breather" on a catch can other than a pressure relief valve. Normally being routed before the turbo the crankcase breather is under vacuum

I have the Flashlube Catchcan Pro, it was $229 from supersheap, it has 19mm fittings (you need to find some 16-19mm connectors) and a filter that should be replaced every 20,000kms, the genuine filter is about $90 although an aftermarket filter is about $35. I've caught about 400ml of oil in about 9000kms.

The Provent 200 is another popular one which I think has 25mm fittings. The HPD one doesn't perform well as it uses steel wool for the baffle which doesn't condense a lot of oil.


ARE is a good place to look for all things regarding intercoolers
https://www.are.com.au/Inter/topMountIntercoolers.htm

[Oddie1969]

You need to remember its only a 3ltr it will only go sooo fast.
making it more efficient would be a better goal imo
Sounds like you got a great deal.

I’m not needing it to go fast, I’m just trying to get as much power as I can to tow our new caravan.

[Oddie1969]

You should definately fit a catch can, and not a cheapy from ebay because they don't have a baffle and are essentially useless. Also I don't think you really want a "breather" on a catch can other than a pressure relief valve. Normally being routed before the turbo the crankcase breather is under vacuum

I have the Flashlube Catchcan Pro, it was $229 from supersheap, it has 19mm fittings (you need to find some 16-19mm connectors) and a filter that should be replaced every 20,000kms, the genuine filter is about $90 although an aftermarket filter is about $35. I've caught about 400ml of oil in about 9000kms.

The Provent 200 is another popular one which I think has 25mm fittings. The HPD one doesn't perform well as it uses steel wool for the baffle which doesn't condense a lot of oil.


ARE is a good place to look for all things regarding intercoolers
https://www.are.com.au/Inter/topMountIntercoolers.htm



Looks like a catch can is the next thing on my shopping list.
I was looking at this one https://demonproparts.com.au/products/dpp-aluminium-billet-oil-catch-can-kit-to-suit-nissan-patrol-zd30-3-0l, I don’t know if it’s any better but it looks like it has the 16mm fittings.
Thanks for the ARE link, there is some good information on there :thumbup:

[Bidja]

CC is a good investment. I run a Provent 200, few dollars but one of the proven designs. Try Western Filters.

Now that you have installed the new TIG welded cooler, guess you would have cleaned the air intake pipe to turbo and boost hoses, at least the one from turbo to the new cooler "hot side" _ by pulling some rag through??

[Oddie1969]

CC is a good investment. I run a Provent 200, few dollars but one of the proven designs. Try Western Filters.

Now that you have installed the new TIG welded cooler, guess you would have cleaned the air intake pipe to turbo and boost hoses, at least the one from turbo to the new cooler "hot side" _ by pulling some rag through??

Ummm, no :frown:

[Bidja]

Just good house keeping. Was there much oil residue in air intake duct (airbox to turbo) or boost hose from turbo to cooler. Give them a clean mate.

[Oddie1969]

Just good house keeping. Was there much oil residue in air intake duct (airbox to turbo) or boost hose from turbo to cooler. Give them a clean mate.

I didn’t look at any of those ! I was more worried about making sure I didn’t break the engine while changing the intercooler, I will be checking all these things this morning, thanks.

[pollenface]

Looks like a catch can is the next thing on my shopping list.
I was looking at this one https://demonproparts.com.au/products/dpp-aluminium-billet-oil-catch-can-kit-to-suit-nissan-patrol-zd30-3-0l, I don’t know if it’s any better but it looks like it has the 16mm fittings.
Thanks for the ARE link, there is some good information on there :thumbup:

It has a stainless mesh filter so will not likely be as good at catching oil as the Provent or Flashlube CC.

[Oddie1969]

It has a stainless mesh filter so will not likely be as good at catching oil as the Provent or Flashlube CC.

Ok good to know, I will get one of the other ones, thanks.

[mudski]

Mann & Hummel Provent 200 is the best on the market in my opinion. The drawback, they are pricey if you want a simple kit to fit up. Buying the can itself is cheaper of course but you then need to make your own bracket and plumb it in. Not hard if your handy with this stuff.

[Niftyjk]

Guys

Thanks for the info. My son has just purchased 2001 Nissan Patrol and intercooler is leaking oil. Very new to this. Is this engine oil or something else as my understanding intercooler is air only. Can anybody recommend an aftermarket replacement please.

[Niftyjk]

Mate, son just brought a unit and the intercoooler is leaking oil. Can I ask where you got yours from and is it welded please - Nev

[Bidja]

Guys

Thanks for the info. My son has just purchased 2001 Nissan Patrol and intercooler is leaking oil. Very new to this. Is this engine oil or something else as my understanding intercooler is air only. Can anybody recommend an aftermarket replacement please.

Nev, the oil residue that is evident on your sons intercooler (eg: most likely where the core mates with the crimped end tanks_if not a welded construction).

Extract from Western Filters web page

With late model diesel emissions systems they are required to return internal fumes from the top of the crankcase and back to the Air intake system. This air often has tiny droplets of oil called Blow-by, and over time accumulate clogging up Air Intake Manifolds, Intercoolers and Turbo Chargers, generally reducing performance of your vehicle. EGR Valves & Coolers are also affected turning the normally dry carbon or soot into a sludgy tar like substance again slowly reducing performance and economy of your vehicle over time.

Most install a quality Catch Can that will trap a good +90% of the oil (Blow-by) and prevents it from going into your air intake system. Very good investment.

Where is the oil evident on the intercooler, maybe the air intake pipe that clamps up to turbo and what about the boost hoses in and out of intercooler. Any pics of intercooler/leaks?

Some of the other members may suggest a reasonable priced quality welded cooler (even heard of good quality/budget ones of Ebay), just depends on your Budget and future intentions with eng mods.

[Grant209]

Guys

Thanks for the info. My son has just purchased 2001 Nissan Patrol and intercooler is leaking oil. Very new to this. Is this engine oil or something else as my understanding intercooler is air only. Can anybody recommend an aftermarket replacement please.

Hi Nev

As Biftyjk said, the oil is collected via a Crank Case Breather and feed into the Air Intake just before the Turbo, most post 1980's vehicles have this type of setup now due to Vehicle Industry Anti-pollution Rules, in the past the vent tube was just vented straight down onto the road.

My truck is a 2013 build. The Catch Can I fitted is a SAAS Baffled Catch Can purchased from Autobarn for only $130 odd dollars. This is the second SAAS Catch Can I have fitted, the first one fitted in my 2012 Navara D22 for about 6 years.

Your Son's intercooler will look something like Mine on the underside as I'd say, the top of My intercooler was the same as the underside when I got it, but I wash my engine at lest once a month, so the top of the intercooler has been cleaned a few times this year and is much cleaner then the underside,

I removed my intercooler about a week ago, so the oil residual on the underside of the intercooler is 7 years worth, So I took the opportunity to hit it with the pressure washer while it was off. Also remove a lot of oil and dirt from the core as well.

Before Pressure Wash Cleaning
81944

After Pressure Wash Cleaning
81947

After installing the My Catch Can in March, the Catch Can removes about 20-30ml of oil a Month, I've never flushed My Intercooler Out after installing my Catch Can, I use to have oil just oozing out of my hoses when I removed them, now I have a couple of drops of oil every 10sec's, so nowhere as bad as I use to have going through the intercooler.

The following photo's shows how much oil residual still goes through even with My Catch Can.

The Intake Hose from the Intercooler
81945

Turbo Outlet
81946

Since installing the Catch Can, My Air Intake Hose to the Turbo has nowhere near as mush Oil Residual sitting around the hose base.

I've been meaning to Flush Out the inside of the intercooler to remove the built-up oil from over the years, just haven't got around to it yet . . . maybe in the next month or so now we are getting warmer days to help dry it out.