Jump to content


Photo

Tdci Intercooler Question


  • Please log in to reply
90 replies to this topic

#1 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 16 July 2014 - 06:29 PM

Hello there not sure if this has been asked before but has anyone removed an intercooler. I only ask as I have finally got an aftermarket one. It's a direnza one and the guy who had it's previously said it's amazing on his diesel. So I'd imagine jack the car take the lower engine covers off to gain access to jubliee clips. Remove lover grille to access the mounting brackets and then remove the cooler. The one that's coming is roughly the same size just a thicker core. So if anyone knows would be much appreciated for some information on it.

Ryan

Have something to contribute?

Sign in or register to start a topic...

Sign up to FOC Premium Membership To Remove These Ads

#2 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 17 July 2014 - 10:25 AM

Anyone?

#3 IINexusII

IINexusII

    Feet Under The Table

  • FOC Supporters
  • 377 posts
  • Name: James
  • Ford Model: Focus 1.8 TDCI Zetec Climate
  • Year: 2006
  • Location: London

Posted 17 July 2014 - 11:10 AM

you should find the instructions in the haynes manual



#4 salsheikh

salsheikh

    Sal_Sheikh

  • True Ford Enthusiast
  • PipPipPipPipPip
  • 1,553 posts
  • Name: Sal
  • Ford Model: Focus 1.8 Turbo D
  • Year: 2008
  • Location: Warwickshire

Posted 17 July 2014 - 12:56 PM

i think mate you need to remove the front bumper to gain access to some of the bolts but i do belive it can be done without taking the bumper off.

 

have a look on the forge motorsport website as they normally have 'how to' guides.



#5 troy45

troy45

    Feet Under The Table

  • FOC Supporters
  • 430 posts
  • Name: Troy
  • Ford Model: Focus ST
  • Year: 2010
  • Location: Cheshire

Posted 17 July 2014 - 09:09 PM

If the set-up is anything like the ST then if space gets tight for removing the IC or fitting the newie , unbolting the radiator cradle from the underbody can help drop everything down.

 

Pretty sure the standard ST IC is very similar mounting to that used on tdci's in any case, undertrays off then 1 bolt at each end going into j-clips and of course jubilee clips as well. The cooler prob then just hangs on plastic fingers on the radiator assembly, so needs lifting up and off it comes.

 

If a bigger intercooler is going in you may need to relocate the horn, the IC may have a lug mounted for this, and be extra careful you don't disturb the cable from the upper grille to the bonnet latch. Also from my experience it's been hit and miss how well aftermarket IC's fit and what unexpected modifications are needed so be prepared for taking it on and off a few times, and finding the knack for the flightpath needed to get it in position.



#6 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 18 July 2014 - 06:20 PM

That's one thing I don't have and I should really one. The intercooler is the same size and as the standard one perhaps slightly thicker but also it's faster flowing. So it should be fairly straight forward. You can get to most of it with just the grille off so I'd imagine I'll just take the flooring off and go from there. Is imagine it will go in and out a couple of times but who knows. I'll see how I get one I'm sure I'll find away with taking the bumper off. I don't have to touch the upper grille for that do I? Is imagine I do. The lock will be ok as it's a brand new lock for free courtesy of ford. It retails at 170 then fitting on top of that.

#7 salsheikh

salsheikh

    Sal_Sheikh

  • True Ford Enthusiast
  • PipPipPipPipPip
  • 1,553 posts
  • Name: Sal
  • Ford Model: Focus 1.8 Turbo D
  • Year: 2008
  • Location: Warwickshire

Posted 18 July 2014 - 06:29 PM

You have a pre facelift focus and the forge guide will come in use. There is also a website where someone has made a guide on thebumper removal called james something where he has upgraded his bumpers et

Sent from my GT-N8010 using Ford OC mobile app

#8 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 18 July 2014 - 06:37 PM

No my focus is a mk2.5 and not a mk2. I think I know who you are on about. I'm sure I'll find out. Like I said I maybe able to donor without bumper removal. Here is a picture of my new cooler which will be arriving tomorrow afternoon.

Screenshot_2014-07-18-14-20-03_1.jpg

#9 troy45

troy45

    Feet Under The Table

  • FOC Supporters
  • 430 posts
  • Name: Troy
  • Ford Model: Focus ST
  • Year: 2010
  • Location: Cheshire

Posted 18 July 2014 - 06:53 PM

Definitely do-able on the ST without taking the bumper off, or taking the grille out, if you can get under the car and drop the undertrays off.

 

Unless your engine type wasn't used on the Mk2 you'll probably find everything mechanical under the bodywork is the same as the pre-facelift cars so the guide will still be very useful to you. If your new IC is same height as the original then your lock cable will probably not get disturbed - more likely when you're fitting a much taller IC in there and can't see what's going on up top while fitting it from below. Just to be save you can operate the latch with a screwdriver while the bonnet is up and check your key releases it ok - much easier job to fix before you put the bonnet down and find you can't open it again :(



#10 Lenny

Lenny

    Retired Moderator

  • FOC Supporters
  • 9,660 posts
  • Name: Leonard
  • Ford Model: Focus ZetecS
  • Year: 2010
  • Location: Ireland
Contributor

Posted 18 July 2014 - 06:59 PM

Look forward to the test drive review after fitting,

#11 salsheikh

salsheikh

    Sal_Sheikh

  • True Ford Enthusiast
  • PipPipPipPipPip
  • 1,553 posts
  • Name: Sal
  • Ford Model: Focus 1.8 Turbo D
  • Year: 2008
  • Location: Warwickshire

Posted 18 July 2014 - 07:23 PM

Oops my bad. That ic doesnt look muh bigger than a standard ic. Igd go for something a bit bigger mate for you to notice any gains. Sorry

Sent from my GT-N8010 using Ford OC mobile app

#12 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 18 July 2014 - 08:12 PM

That's ok not a problem. Well I've bought for a bargain and the car is being mapped in a couple of months with Dpf removal and exhaust fitted so I thought may as well remove another restriction. The guy had this cooler on his st and he said it worked really well if your just doing a stage one which is basically what I'm doing and with this add on he gain 11bhp before he had his car mapped. Now I may never gain that much before hand but it gives you an idea on how much of a better flow the cooler is. Before I install it I'll be giving it a good clean inside and out to remove any FOD before install.

#13 footfistart

footfistart

    Feet Under The Table

  • Budding Enthusiast
  • PipPipPipPip
  • 245 posts
  • Name: Ryan
  • Ford Model: mondeo TiTx Sport 173
  • Year: 2009
  • Location: Surrey

Posted 18 July 2014 - 10:10 PM

Sorry troy I didn't see your post. That sounds promising. Well my car is a 60plate and being one of the last lot to be made before the new shape arrived. So I'd imagine things have improved and been moved ect ect. I guess we will see how it goes. If it's the case of dropping the undertray and removing the lower grille then it won't take long. I've just seen your post you sent me about bumper removal. Sounds complex and a two man job. Thanks for the iinformation.

#14 troy45

troy45

    Feet Under The Table

  • FOC Supporters
  • 430 posts
  • Name: Troy
  • Ford Model: Focus ST
  • Year: 2010
  • Location: Cheshire

Posted 18 July 2014 - 10:33 PM

In reality the last cars of a production run will have all the updates that have filtered through from warranty issues etc but will also have been subject to lots of cost-downs where Ford will try and reduce production costs. And once a new model is not too far away they'll cut right back on investing any more money in engineering changes unless absolutely necessary.

 

I hadn't realised myself just how much work was involved getting the front bumper off, on the other hand I've had lots of intercooler changing practice - simplified a bit but basically main undertray and bumper undertrays off, then do everything from under the car. You'd save yourself from having to remove the lower grille then, if it clips in same method as the ST the locating tabs go into letterbox slots in the bumper and it's pot luck how many of them break when you basically have to just pull the grille out  :rolleyes:

 

Hope it all goes ok whichever way you decide to attack it :)



#15 FOCA

FOCA

    Feet on the table

  • True Ford Enthusiast
  • PipPipPipPipPip
  • 2,798 posts
  • Name: FOCA
  • Ford Model: Mondeo Mk3 Sleeper 194 flb.p.t.
  • Year: Non
  • Location: Scotland
Contributor

Posted 19 July 2014 - 04:02 AM

Oops my bad. That ic doesnt look muh bigger than a standard ic. Igd go for something a bit bigger mate for you to notice any gains. Sorry

Sent from my GT-N8010 using Ford OC mobile app

It may flow better because its thicker (so the cross-sectional area is greater) + being made of alloy instead of steel means its thermal properties are better - both may increase power (even if its just a little) + allow the remap more potential gains

 

Going too big on the intercooler may often be a mistake, as it may increase lag/ raise the boost threshhold



Have something to contribute?

Sign in or register to start a topic...


Not what you're looking for?

Register now, we have a huge community of enthusiasts to answer any questions you might have



0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users