(T) Fitting a bigger intercooler

Whats the rad on the left corner, if its not a intercooler what is it and is it not on the wrong side if it is a standard intercooler.

Nice set up though. What power you running with that and you got a Jtd or multijet?

oil cooler

Jtd 150 16v, yes it's std oil cooler.
Forgot to mention you'll struggle to get fmic in place without a few mods to grills bumper etc.
That's flowing enough for 95.5mg/i fuel with afr 16.5:1 @ 1750mbar around 4000revs and only 12*c above ambient. Hopefully around 440nm@2750 and 410nm@4000
Hybrid turbo and fully decated help no doubt.
No r/r print out so please don't ask, these figures are from the figures in map as requested(already minus internal friction loss from its own map, requested nm is closer to 490nm)

if it helps ive dug back and ill try to get all related pics up in here.
here is available frontal area in cowel



old vs new

cut crash bar and bolted through from above

rough idea fom above where its siting

tried to keep bends fairly tight, youl see why in a bit

hopefully other models have less other stuff in the way and a better route is available

required drastic surgery to cram in


you can see black cut lines marked in central grill

you can see no route with original grill openings


large amount taken out of side grill opening

thinner new grills

painted black at finish due to being a bit blingy through the grills
a slightly shorter fmic would have helped a lot with grill and bumper mods im guessing, but this one is maximising the available airflow.
ive seen a few massive intercoolers on some cars that 1/3 of the frontal area is covered by crash bars etc just seems a waste to me.
if id have known how hard to cram it in i would have got the intercooler outlets cut and rewelded at an angle would have helped a bit.

Hats of to you, that is one really tidy install.

So what power output are you getting with that bigger inter-cooler and any other engine mods, Guess you have a trick turbo??

hp?enough.
ill start another thread for the hybrid turbo.

i think this was a recent data log.
http://www.alfaowner.com/Forum/attac...-new-map-2.xls
not bad +7*c to +14 map to maf temp, at nearly 1.8 bar.

just a graph from data on bottom of page 1

more old pics

























in this last pic if you can zoom in you can see where I had to cut and remove some plastic to allow a closer line around , sheet ally sealed and stuck over area as I still have boost solenoid behind there so want to keep it dry.
was a toyosports universal kit, but required a few mods to bend angles here and there.
the silicon bend on the corner by the oil cooler eventually blew off so I cut my losses and tried a ebay hts2000 weld kit (like a solder for ally)which so far has not failed (no pics of this job im afraid)

just been under car doing aux belt , found the long section of intercooler pipe with no support from the arch liner has been rattling on the bumper.
so using the old aux belt as a nice support strap ive hung it on the what I think was the exhaust downpipe/cat bracket.
and also theres a pic of where I swapped that silicone angle for a hts2000 welded corner piece and a pic of the weld( not pretty but does the job and diyable in garage with plumbing torch)