3.0L Replacement Intercoolers

This is more of an info thread/done today, so admin feel free to move it.
I have done a fair bit to looking around for replacements for my famously popular leaking 3L Intercooler. After the initial call to Nissan and the ridiculous asking price for the factory unit and the inevitable future failure, I have found two great options that I thought I would share. The two options are more based around your financial situation and amount of time spent in low speed high rev situations.
Option 1. Cross Country 4x4 - GU Patrol 3.0L Intercooler Upgrade - $1250
These units seem like an ultimate option with a much bigger core and thermo fan. (Note this requires some alteration of the intake scoop rubber and I assume the plastic engine cover doesn’t fit back on. Don’t be afraid though as this seem relatively simple) With a thermo fan installed underneath the core this should remove airflow blockages caused by the usual top mount fans at higher speeds. They use a PWR developed core (from my understanding PWR do most of the V8 racing car cooling).
Attachment 5532 Attachment 5533

Option 2. PWR Performance Products - Patrol 3.0T Changeover Top Mount - $649
This product is an exchange based system where they take the tanks of the old unit and replace the core with a new one (Better Quality, same physical size) and TIG weld it in. These are an exact replacement for the original so no modification is required.
This one was my end choice due to financial constraints and the lighter offroad use due to it being my daily drive. I had the luxury of them being based at Ormeau QLD, which is close to me. For others they offer in most cases an advanced replacement option of leaving a deposit until your original unit is delivered to them. I have also found a company offering these units with the PWR core on ebay for around $599, but by the time I paid freight back and forward it was about the same and I could get an instant replacement.
Attachment 5535

Original Factory unit to compare:
Attachment 5534

Thanks Scotty. What was the price at Nissan?

Tony

OEM Nissan one is about $1200. Nissan changed twice on my car under warranty.

There are a third choice that someone in the patrol4x4 also do a replacement unit using the original end tanks. Can't remember the cost thou.

Just a quick update on this. all is going GREAT. had to relearn how to drive my car as i hadn't realised how sluggish it had become with the leaking intercooler. very surprised.

I have found another alternative - ASE, has anyone fitted one of these?

http://www.aseturbo.com/NISSAN-PATRO.../prod_384.html

I did fit one of these about 2 weeks ago to our '05 ZD30. Had the EGR blocked as well. Seems to spool up quicker and rev more freely. Probably more fuel effecient as well. Can't put the engine cover on after installation.

Another alternative is ARE Cooling. Seems like they have done some serious testing with various configurations, including bigger bonnet scoops. Suggest a look at this website. It is very informative.

http://www.are.com.au/Inter/topMountIntercoolers.htm

Hi Scotty
Have looked at all the same and have convinced self that A.R.E. kit is way to go as I will be doing pilot/escort work, which means I will be sitting close behind wide loads as well out front, so the fan on the ARE cooler with the bigger scoop will come into it's own, but have to fit piro & boost gauges first,

Good Luck

Choppie

I'm planning to buy the cross country 4x4 intercooler (if they ever get back to me... What is it with companies not responding when I just want to hand them volumes of cash with no fussing around?). Will post about how it turns out when I get one

Hand the volumes of cash to me then :) On a serious note. How can CC justify the price of their IC's? I would love to have one but no way in hell at that price. Especially when the benefits won't be justified by their price. Price gouging at it's best...

It is a good question, the larger core and non-exchange basis can explain away some of the extra cost but it still leaves a lot unaccounted for. I wouldn't be trying to get one if it wasn't for a generous tax return this year. Will make sure to do a thorough post when I get the thing

i have the crosscountry ic and works very well. I could be wrong here but the are ic with the optional bigger scoop may be illegal in some states as the taller scoop may affect vision.

If I got pinged for the taller scoop I'd be asking why, does not affect forward vision in any shape or form.
May be passenger car law, like reverse mounted scoops being illegal.
Just purchased a fully tigged IC from Diesel Smart, under $400 changover,
Pressure tested to 60psi,
33% bigger
And 5 year warranty
No alterations, very impressed, You'll know their IC as it'll have pic of my motor.
I have no affiliation with DS.
And totally agree with Mudski on the price of some Intercoolers.
Try pricing some cores, You see how much your ripped off.
Diesel Smart do a change over IC as well
Check out an IC from an XR6 ford, will need WRX style scoop though
$1300 plus just to have EGTs 50 degrees cooler than mine, what for that's half a diff lock LOL

i think ARE and cross country are good brands regardless of price and which ever you choose is a personal preference. what ever you choose is got to be better than Nissan's. but with ARE ic i'm not sure on the scoop. i must admit that what i have read about the scoop sounds likes a very well tested product however I know for a fact that in QLD, modifications to vehicles need a mod plate. how I found out was I changed troll into a 2 seater having storage draws full length to back of the front seats. when getting this past by a modification plate inspector he told me my long ranger fuel tank needed one as well. reason is any mods need a mod plate to legally registered, and may well do with insurance claims in the event of a accident if determined to have contributed to it.

I have the same scoop as three dogs has, does not block my vision at all
Also does not make a huge difference anyway.

I went with the ASE, I didn't like the CC as I don't believe that a pressure vessel should have sharp edges. I was very happy with the ASE although I guess it's hard to say categorically without an IAT gauge.

Just an Update now I've had the new Diesel Smart IC fitted, I also have the larger scoop.
First I drove so get some fuel figures, managed to return 12.8 around town. Now I'm driving it a bit harder
and noticed boost was very high 15psi at 100 kph, due mainly to leaking IC not leaking now. I've reduced boost to
10psi at 2000rpm EGTs are low and stable . Have some steep hills over our way and can floor it from the bottom and EGTs are fine.
Happy as a pig in poo. If you after and aftermarket change over IC I would recommend Diesel Smart, change over for around $400
gotta love that

Hi guys
I have a 2001 GU. I have been told my intercooler is leaking. Is there a way I can tell for myself. My concern is weather its the intercooler or the turbo

An introduction thread gets you better answers mate. Look for oil spray along the crimped edges also a boost gauge would help too. Being so old no doubt the factory cooler s leaking but the turbo would be close to its end too.