Adding an intercooler to a 4D56 turbodiesel engine

[Ikabod]

I recently bought a '92 Pajero GEN 2 (previous owner got it from ADB) fitted with a 4D56 turbo diesel engine. I'm thinking about increasing the power a bit by adding an intercooler but I'm hesitant about a few things I'll probably encounter in this project. My questions are:

1.) Can I add an intercooler to my engine without doing any modifications on the internal components of the engine? I don't want to replace the engine with a surplus TDIC 4D56 engine because I don't really have the budget for it. And besides, the engine is in excellent working condition.
I just want to know if it would be feasible to add an intercooler because of the added power it would bring.

2.) Will the engine be strong and reliable enough to accomodate an increase in power brought about by the addition of an intercooler? Is it advisable to add an intercooler in this situation?

3.) If it is feasible to bolt on an intercooler to my engine, what parts/components do I need to successfully upgrade my turbo diesel engine to a TDIC engine?

I'd really appreciate any info and advice you guys can give me about this idea of mine. Thanks in advance.

[Yellow]

You can add an intercooler, you wont need to replace anything, all you need to do is buy an intercooler designed for your pajero. There are intercoolers for your pajero model in banawe surplus shops. The added HP wont be that much that the engine cant accomodate it, it is a good idea to add an intercooler, I don't know if you would need modifications probably the mouting brackets for the intercooler would need to be fabricated.

[KCboy]

actually tulong nga kung may intercooler kc it would cool down the warn air that enters trhe engine making ur engine more efficient n run better, if anything, better performance lang n not much increase in power. dats the turbo's job, i'm sure u can do that n if u ever do that, try luking for a hood that has a hood scoop para todo porma na, under 10k na yung hood with scoop. get pajero kid's number, he has a hood with a scoop for u.

[pajerokid]

if you want to add an intercooler, i think you have to get a new intake manifold, aside from the intercooler assembly. I checked out some 4d56T's in Banawe and i found that magka-iba ang itsura ng intake manny nila. Of course you could get aroung this problem by modifying the hoses, thats if you dont like to go stock :D

And tama si kc. To maximize your new Intercooler, better check the hood. Intercooled pajeros have special air ducts underneath the hood to feed the intercoolers cool outside air(Gen2 95-97). Of course, 2.8L models have the hood scoop (wala na pong ducting coz the air comes directly from outside).

hope this helps :D

[Ungas]

Before installing an intercooler for your engine, you may want to try it first on offroading. Then unleash the real power that your engine have. (that is if you are only interested sir. :D )
Then feel your engine if it really needs power that you may want to add. :mrgreen:


Join us in our next offroading excapades, it's fun! (parang napapansin ko dumadami na mga Pajero boys dito :mrgreen: )




Just my 3 cents.. ay! 2 cents pala, typo error.

[OTEP]

You don't need to modify the internals of your engine to accomodate an intercooler. An intercooler does not add any undue stress to your engine.

An intercooler is basically a heat exchanger (radiator) for the air that's coming in. It has no moving parts other than the fan underneath it making it pretty reliable.

Most changes will involve the intake plumbing. Madali lang naman iyon as long as you have the right parts.

You may want to get a double-wall (4D56 TDIC) or a scooped (4M40 TDIC) hood to help the intercooler breathe better.

Horsepower will go from around 84 bhp to 99 bhp.

Try to join the off-road trips. There you will learn that its not always horsepower that counts. I learned that a lot the last time I was with them.

[afrasay]

Ikabod:::Yon engine ko no turbo, ok naman sa offroad. Upgrade lang ako ng tires.

UNGAS, PAJEROKID, KCboy:::Kaya I like to replay our level 2 run natin sa PORAC.

Otep:::I know what you mean. :wink:

[afrasay]

Ikabod:::Yon engine ko no turbo, ok naman sa offroad. Upgrade lang ako ng tires. One set of turbo (surplus) cost P15,000. May kasama ng intake and exhaust manifold and the injection pump or the flapper only

UNGAS, PAJEROKID, KCboy:::Kaya I like to replay our level 2 run natin sa PORAC.

There you will learn that its not always horsepower that counts. I learned that a lot the last time I was with them.

Otep:::I know what you mean. :wink:

[KCboy]

next year cguro alfred try natin yung level 3. si jan paurong kc. he tried level 3, 2, then1 kaya pabored sya ng pabord sa offroadinmg. less challenging. bitin yung last natin.next year cguro alfred try natin yung level 3. si jan paurong kc. he tried level 3, 2, then1 kaya pabored sya ng pabord sa offroadinmg. less challenging. bitin yung last natin.

[pajerokid]

ikabod::: Pare, adding an intercooler makes sense! An addotional 15 horsepower is certainly useful for everyone. And besides, 4D56turbos and 4d56turbo intercoolers have exactly the same internals (note: Normally Aspirated 4D56s are different!).

A more powerful engine is surely an asset onroad. You know, for overtaking, fuel economy etc. But i back up what the peeps said about offroading. Yung aking hamak na 99hp 4d56 lumalagari! Whats more important offroad is (IMO) the performance of the transfercase and differential. (VIVA Super Select!!! :mrgreen: )

[OTEP]

UNGAS, PAJEROKID, KCboy:::Kaya I like to replay our level 2 run natin sa PORAC

Ito ba yung kasama ako? Gusto ko din ng replay!

[Ikabod]

Sorry for the delayed response, I was kind of busy yesterday. By the way, thanks for all your inputs, I really appreciate it. Anyway, the reason I was inquiring about adding an intercooler was mainly because I already noticed that the hood had the ducting necessary for adding an intercooler and it would be a good idea to make use of it since it was already there. Actually I'm not really into offroading, another reason I wanted the extra power was because the Pajero is our main family car and since we go up to Baguio often and haul a lot of stuff, I figured it wouldn't hurt to have that additional power for the trip.

One question though, how difficult and expensive would it be to get all the parts/components necessary for the upgrade? I'd like to keep everything to factory spec and use as little fabrication as possible. Also, where can I get the parts I would need for this project?

[Yellow]

Ikabod,
A surplus intercooler complete with fan and brackets costs 8500 at banawe, question is if you can find one, most of the shops that sell surplus engines there won't part with the intercooler with out the engine. I just got lucky that a shop had a 4D56 TDIC engine that took in water so the engine was no use, chop chop na I got the intercooler.

[pajerokid]

Yellow::: youre one lucky guy! :D diba you bought woodfire's engine? Anyways, 8500 is a good price for an intercooler assembly :D goodluck in finding one ikabod!!!

Otep, Alfred::: Parang gusto ko ay level 1.5 lang hehehe :D magastos sa ball joint hehehe :D

[Yellow]

pajerokid,
Yep I got woodfires engine, swerte ko nga sa intercooler may fan pa! sariwa pa yung fan.

[OTEP]

pajerokid,

Lower balljoint lang naman ang most probable na masisira sa off-roading, eh. Don't bother replacing the upper ones para iwas gastos. Yung upper balljoint basically has no load on it. It's only there to keep everything in place.

[Ikabod]

Thanks again for all the advice you guys mentioned. I'll probably just be on the lookout for an intercooler kit. I hope I'm as lucky in finding as you were Yellow.

[Ikabod]

Thanks again for all the advice you guys mentioned. I'll probably just be on the lookout for an intercooler kit. Yellow, I hope I'm as lucky in finding one as you were.

[kimpOy]

hmmm replay is in the works!!!

next year ba ninyo gusto???

[Yellow]

Ikabod,
I'll be dropping by banawe this week, I'll try to look for one, I'll post here if I do find one.