My new FMIC (91 SB engined GTD A2)

[GTD.]

I 've just fitted an intercooler out of a old volvo 5cyl petrol turbo estate to mu UK spec 91 A2 GTD with SB engine
















Click the pics for larger 1024x768 versions

I had to grind the front of the lower radiator support to get it to fit and I'm going to have to fit the battery in the boot so I can route the intercooler outlet tubing.

[vwmike]

That's funny.... I thought about doing that but that intercooler is just so tall I figured it probably wouldn't fit unless I went to big bumpers and just removed that lower valance. The only downside is what the volvo guys run into where the tanks like to blow off if you run a lot of boost. I've heard they like to wrap ratcheting tie straps around them to hold them together.

[GTD.]

That's funny.... I thought about doing that but that intercooler is just so tall I figured it probably wouldn't fit unless I went to big bumpers and just removed that lower valance. The only downside is what the volvo guys run into where the tanks like to blow off if you run a lot of boost. I've heard they like to wrap ratcheting tie straps around them to hold them together.

 :shock:  How much is a lot of boost? I'm currently running 0.8 Bar and was considering 1.1-1.3 Bar.

I had to fit a smaller radiator out of a 88 1.6 auto A2 Golf but the water temp has only gone up 10°c

I only paid £10 sterling (Aprox $18 US) for the intercooler and some boost pipes off the Volvo and a Peugeot 405 TD.

[Maarten]

Nice IC... but maybe its a good idea to clean out your radiator, it looks stuffed! If less air can pass trough the radiator, less air will flow through the IC.

Can you write down the partnumer of the dieselpump for me, I'm trying to figure out what the difference is compared to the 70hp JR TD's (for possible pump/injector swap)

[fspGTD]

Nice work!  With the large thin core, that intercooler should be effective at even very slow vehicle speeds I would think.  Were you able to install that with the complete A2 radiator support or was cutting necessary?  I'm sure cooling efficiency is going to be very high with that intercooler and the proper air baffles.  You should consider blocking that big gaping hole next to the intercooler, as well as any other paths where air can escape around rather than through the intercooler.  Let us know if you get any data as to pressure drop.

[sethyboy85]

volvo IC pops it's endtanks at like 15psi... use ratcheting straps or bungee cords to avoid one at top and one at bottom. IC flows well (low pressure drop) but does not cool that well because it is not internally finned but does flow ok... it IS better than nothing and not that bad of a IC

[GTD.]

Nice IC... but maybe its a good idea to clean out your radiator, it looks stuffed! If less air can pass trough the radiator, less air will flow through the IC.

Can you write down the partnumer of the dieselpump for me, I'm trying to figure out what the difference is compared to the 70hp JR TD's (for possible pump/injector swap)

I'll have a look tomorrow for a part number, I'm also going to clean my entire bay with red (uk untaxed) diesel and a steamcleaner at my mates works this week if he gets a long lunch break.

Nice work!  With the large thin core, that intercooler should be effective at even very slow vehicle speeds I would think.  Were you able to install that with the complete A2 radiator support or was cutting necessary?  I'm sure cooling efficiency is going to be very high with that intercooler and the proper air baffles.  You should consider blocking that big gaping hole next to the intercooler, as well as any other paths where air can escape around rather than through the intercooler.  Let us know if you get any data as to pressure drop.

I had to cut only the leading edge, and the bracket for the valance/slam panel off the radiator support cross member as shown in this pic

click pic for 1024x768 version

I fitted this IC because it was avalable, looked easy to fit and has round outlets, I saw a Peugeot 405 TD one in the same yard but it had a flanged outlet that coupled strieght to the inlet manafold and is mounted simiular to the subaru sti ones above the eninge so suffers with heatsoak in standard locaton and also wouldnt mate up to the vw manafold.

I did have the "Euro" MK2 (A2) GTD itercooler it wasnt getting any/enough cold air though it (possibly as I currently dont have the entire cowling fitted) and was suffering from heat soak, turning it from an intercooler to an interwarmer.

volvo IC pops it's endtanks at like 15psi... use ratcheting straps or bungee cords to avoid one at top and one at bottom. IC flows well (low pressure drop) but does not cool that well because it is not internally finned but does flow ok... it IS better than nothing and not that bad of a IC

Thanks for the heads up, I'm not running that much boost, yet... but soon hope to, the Volvo IC should be better than my stock VW one I'm running untill I relocate the battery to the boot, I'm going to trawl the breakers yards on monday looking for a battery box big enough to take my Quantum 096 diesel battery, then make up the cables to relocate the battery.