intercooler installation on 1988 Jetta Turbo Diesel

[chrissev]

I've decided I want to put an intercooler in my 1988 Jetta Turbo Diesel and have some questions about how to do it.  Firstly, if I just run the plumbing, connect the intercooler, and find a good place for it, without adjusting the turbo or the fuel injection pump at all, will it work or will I cause some sort of damage to the turbo?  
What intercoolers would you reccommend for this car?  I am hoping to get one out of a junked car in a scrapyard.  
If I put the intercooler in front of the radiator will it affect the cooling of the engine?

Thanks,

Christopher

[QuickTD]

Here's a sample of some intercoolers available at the junkyard. Almost anything can be "perverted" to fit. What you choose to use will depend on your fabricating skills and the equipment you have available. Lots of good IC info here. Enjoy!

http://www.turbomustangs.com/intercoolers.htm

[fspGTD]

Here's a sample of some intercoolers available at the junkyard. Almost anything can be "perverted" to fit. What you choose to use will depend on your fabricating skills and the equipment you have available. Lots of good IC info here. Enjoy!

http://www.turbomustangs.com/intercoolers.htm

That's a great link, QuickTD, thanks for posting!

[chrissev]

Some brief answers:

Yes, simply plumbing in the IC will work, and won't cause any damage to your turbo. It's also a fact that an IC by itself isn't going to give you much, if any increase in power. The purpose of the IC is to cool the charge air coming out of the turbo, making it more dense, with more oxygen molecules. More oxygen means that you can add more fuel, which means more power. Without the additional fuel, you might expect the engine to have lower EGT's and perhaps take longer to reach operating temperature.

so you're saying I need to also adjust the fuel supply or install injectors with a higher flow rate?  I've seen that the turbo diesel 1.6 engine on my Jetta came in an intercooler version.  Perhaps only in Europe, because I've never seen one in Canada.  Does anyone know what the set up was on this engine (1.6 turbo diesel intercooled)?

[Caddy-Daddy]

Starting from 1989 -1991 VW had an intercooled version of the GTD.
The engine code's were RA and SB
They had different pumps and injectors aswell as an intercooler setup above the battery tray. Almost similar with the G60 engine with aircon.
Although the GTD had the in and outports of the intercooler on top instead of out on top and in on the bottom .

The Turbo was smaller and was watercooled. I'll post some pics if I can find them in my huge collection of pics.  :lol:

[BlackTieTD]

here you go  



mkII with aircon.

..and some more pics of custom IDI intercooler installs from the old forum: http://www.hostboard.com/cgi-bin/ultimatebb.cgi?ubb=get_topic&f=4037&t=678

[Caddy-Daddy]

What about this Mk 2 ?



Fully electronic TDII

[chrissev]

I do get some smoke when I go hard on the accelerator, like during a highway speed pass, so I suppose if I intercooled it that smoke would become extra power.  I'll try to intercool it just as it is and see what happens.


chris

[Caddy-Daddy]

Here is another IntercoolerLink it's dutch but the intercooler sizes are mentioned..

http://www.student.kun.nl/p.oonincx/Intercooler.html

[Josh]

This website about intercoolers appears to have changed, to perhaps http://www.turbomustangs.com/intercoolers.php

You may need to register to see it.  In any case, the "/intercoolers.htm" link no longer works.  

Here's a sample of some intercoolers available at the junkyard. Almost anything can be "perverted" to fit. What you choose to use will depend on your fabricating skills and the equipment you have available. Lots of good IC info here. Enjoy!

http://www.turbomustangs.com/intercoolers.htm

That's a great link, QuickTD, thanks for posting!