Tuning t-jet Bravo aftermarket intercooler - FMIC

[aurick86]

Hello,

So i am thinking that in the spring i would like to replace the intercooler with something aftermarket.. bigger.

I don't really have anywhere to do the work.. to remove the bumper..etc
(i will in the spring, will have some tools at hand)
So i was wondering if anybody has had a chance to measure the space for the intercooler.
Wondering if i could install something like :
180mm x 700mm x 63mm


I will probably still remove the bumper and take my own measurements before actually ordering the intercooler; but i still wanted to ask, maybe somebody has already done the deed, or somebody remembers to take some measurements if they take the bumper off before I do.

 

[aurick86]

Not that much info on this topic i see
Some more info on this: my t-jet is at 194 hp now, i will fit bigger injectors soon (just for safety as the standard ones are about maxed out)...and i might fit the 1.4 Stilo/Bravo NA cams at some point.. if i find them in a reasonable condition/price, but don't plan on upgrading the turbo ..unless it fails .
Basically i don't plan on taking it over 220-230.

So since it was the holidays i had some time to research and get more info:
There are a lot of factors to consider when getting a intercooler (pressure drop, surface area, temperature difference..etc)

The closest thing I could find that might be usefull for regular people like me, are some forum threads for the size of the intercooler:
- 3-litres of volume per 100 bhp = 3L
- a cross section of 50cm squared per 100bhp .. hight x depth = 50cm2

After a bit of research, cross-referencing part numbers, i found out that the Bravo uses the same intercooler for all turbo models except the 2.0 165. that one is bigger.
-51783791 (core size: 572x130x52 => ~3.85 liters and a cross section of 67cm^2) suitable for ~135 hp. it's used in Bravos with the 1.4 t-jet engines both 120hp and 150 hp, the 1.6 diesel and in the 1.9 diesel engines both in 120hp and 150 hp.
-51808365 (core size: 580x144x80 => ~6.68 liters and a cross section of 115cm^2) suitable for ~230 hp. This one is used in the Bravo 2.0, Delta 1.8t, 1.9mjt and 2.0mjt

The only other difference between these seems to be the inlet/outlet, that should be bigger 57mm vs 51 mm, a problem solvable with some 23/45 degree silicone reductions.
The Bravo 2.0 intercooler should use the same mounting points.

Some other minor modifications might be necessary... the shroud might need some trimming.

 

[Ben D]

Hi Aurick,

Is the Bravo IC the same as the T-Jet / Abarth punto? If so, dimensions of Airtec are 820mm X 205mm X 65mm and mounting points will be in the same place. I'm not sure where the dimensions are taken from, some give length including pipe, some give core only and some show core size. Airtec is £295 in UK, I was advised to find something from high end car such as a Mitsubishi Evo or high spec Audi that fits the max dimensions as these are likely to be better than most generic cheap aftermarket FMICs.
I believe the lower part of the shroud around rad and IC needs cutting on the Punto.

Having changed rad on the GP, the hardest part is probably going to be removing the self tappers on the trim fasteners that hold on the bumper.


Cheers

Ben

 

[aurick86]

Hey Ben thanks for the input.
The GP t-jet does indeed use the same OEM intercooler as the Bravo.

That Airtec seems to have overall dimensions...in my view it is still using the 580x180X60 core.. or it's close enough to it.
That also means the overall performance should be similar to the intercooler on the Bravo 2.0.
One thing to take into account is that the shroud really increases intercooler and rad performance ... it basically forces air to go through them and stops most of the air going the easy route.
I plan on cutting as little as possible from the shroud.

I don't rally want to spend a fortune on it.
My whole Bravo "build" has been a series of tracking down good deals, and keeping an eye out on ebay
Then only place where i didn't cheap out was the tune.
I can get a aftermarket OEM replacement for the Bravo 2.0 intercooler pretty cheap .. ~100-120 euro.

 

[Ben D]

How about this?

http://www.ebay.co.uk/itm/ASH-FMIC-Intercooler-Aluminium-Alloy-Front-Mounted-Mount-Turbo-Universal-2-Sizes/190885989165?ssPageName=STRK%3AMEBIDX%3AIT&var=490175941771&_trksid=p2055119.m1438.l2649

 

[aurick86]

Another quick update

I researched the Bravo 2.0 radiator (since this is the support for the intercooler)
It seems that the radiator is 15mm taller .. so to accommodate the taller intercooler.
So the Bravo 2.0 intercooler might not fit after all.

That, and me being so cheap, pretty much leaves me with this one: INTERCOOLER 550X180X65MM

Do you think i need a 23degree 51/57MM or a 45 degree Silicone reducer elbow?

 

[aurick86]

I've found a tuner using those exact parts on the Bravo:
http://trs-racing.pl/fiat-bravo-1-4-t-jet-wymiana-turbiny-na-garrett-gt1446/

That one looks like they're using the 180mm tall core ) that looks HUGE

 

[eclipse1]

Stock core specs:
Height about 13cm
Width about 59cm
Thickness about 55mm

 

[aurick86]

Stock core specs:

Thanks for that... i did know the standard size... but i didn't make it very clear .
-51783791 (core size: 572x130x52 => ~3.85 liters and a cross section of 67cm^2) suitable for ~135 hp

 

[aurick86]

I managed to install the fmic a few weeks ago.

Here are the parts i used :
-Intercooler- 550X180X65 1pcs (you can install a taller one if necessary.. there's enough space)
-T-clamp- 58-65mm 1pcs
-T-Clamp- 64-72mm 3pcs
-23°elbow-reducer- 51-57mm 1pcs
-23°elbow- 57mm 1pcs ( i think a 45° elbow would have been slightly better in my case)

Process:
-Remove front bumper
-remove old fmic +hoses
-cut shroud (i had to cut it as the new intercooler is moved forwards by ~5cm).. i might install it back in if i ever feel like taking the bumper off again
-make support
-install FMIC
-cut and install hoses to fit fmic

I recommend a boost leak test after the installation as mine was leaking badly from one of the silicone joints, slight adjustment and re-tightening solved the issue...

These are the only pictures I took:






Results:
With the stock intercooler:
-on a hard launch and high speed run (ambient temp 22-25 °C) - intake temps 37-59 °C
-city driving (ambient temp 22-25 °C) - 50-65 °C

With new intercooler:
-on a hard launch and high speed run - ambient temp 22-25 °C- intake temps 37-45 °C Huge difference.
-city driving (ambient temp 22-25 °C) - 50-65 °C - As expected- No real difference.
-no appreciable additional lag