Diesel Smart intercooler install and feedback (with pics)

[Hodge]

Well yesterday I finally replaced the leaking factory unit with a Diesel Smart exchange unit. I also installed a catch can in the process and cleaned the MAF so the complete air intake gets a breath of fresh air. Thought I'd share some pics and initial feedback.

I've driven the car for 2 hours after full install, and it's showing improvement straight away. EGT's are down 50-100C around town, and it was a warm day yesterday too. The biggest improvement that I've see is how quick the temps go down when idling. For instance sitting at the lights after a drive, the temps go down much much quicker in contrast to factory IC. Also I'm a turbo cooldown believer, so I do wait for it to drop below 200 before shutting the car down. And now I don't have to wait for long at all, where as before it used to be 2-3 minutes. I'm yet to push the car and see how the EGT's behave then, which I'll contribute here later on.

My old unit was leaking a tiny bit in one corner so this was enough to lean me towards a replacement unit, otherwise I wouldn't have bothered. I was shocked at how much oil came out of the old unit. It caught me by surprise and as I took it out of the engine bay, oil spilled everywhere. Can of degreaser got a workout after this.

New unit cost $450 on exchange basis, was delivered quick and packaged well. If your old unit is leaking, you'd be mad to replace it with another factory unit. I believe this was $450, well spent.

As mentioned I've also installed a provent catch can. Not much to it. And after 2 hours or so driving I figured I'll check if anything's been filtered and the inside walls have a minor coat of out mist. Then I cracked open the exiting hose and intercooler and it was perfectly dry. So thus far it's doing it's job. Annoying part was fitting it physically as I have the battery tray and compressor right there and with the ABS unit and oil lines in the way it's tough squeezing it in. For the moment it's sitting in there zippy tied until I make a proper bracket. Provent with all hoses and clamps was less than $200.

So with these 2 additions to my "NADS" collection, coupled with the dawes and needle valves fine tuned and a clean MAF the car is running like a dream now. I like to think that this has added a few years to the cars longevity.

The old...
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The comparo...
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The install...
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Final product...
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[Fry]

Looking to do the same thing, the only other thing I would like to do is get a bigger scoop.

[Hodge]

Looking to do the same thing, the only other thing I would like to do is get a bigger scoop.

That's my next thing on the cards, to push a bit more air through it. I know of ARE ones, but not sure if other brands or makers exist. Will have to do some searching.

[Fry]

That's my next thing on the cards, to push a bit more air through it. I know of ARE ones, but not sure if other brands or makers exist. Will have to do some searching.

Yeah I was looking at the stealth ones they do, i'm adding up the cost of it all tho and i'm not sure how i'm going to get approval....

[threedogs]

Stropp has a Fairlane branded one drop him a PM for details
Mine is A.R.E. I think

[Stropp]

i think with the standard size cooler a barneys mk2 scoop will be the go, fits into the same hole but is taller and catches more air, come up sometimes in the for sale threads or ebay, i think they are available new from the other forum around $360 unpainted.

[threedogs]

Thanks Stropp my style is more suited to Tig welded OE intercooler,
where as yours is more for the wider IC like the new Diesel Smart one or Cross Country

EDIT::: I have the tigged Intercooler from DS and very impressed

[rottodiver]

I ordered my diesel smart ic last week... Hopefully when I get back to perth the end of the week it will be there..
Scotty

[Hodge]

i think with the standard size cooler a barneys mk2 scoop will be the go, fits into the same hole but is taller and catches more air, come up sometimes in the for sale threads or ebay, i think they are available new from the other forum around $360 unpainted.

Thanks for that mate I will keep an eye on it. Apparently this Barney bloke is a member of the other patrol forum and can make them to order I believe. I wonder if he hangs around here too? I'd just need a taller one, as the hole size is retained to factory size.

[boots]

A pic of the barneys MK2. http://i1249.photobucket.com/albums/...psceb6b350.jpg