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Thread: COMPLETED Project: Intercooler upgrade!

  1. #1
    Join Date
    Feb 2005
    Location
    Italy
    Posts
    44
    My Cars
    BMW 320D touring (136BHP)

    COMPLETED Project: Intercooler upgrade!

    Bought this off Ebay here . (Top right). It cost £67 + postage £27. Clearly it will fit in width and height. Depth may be an issue as it's 76cm as opposed to 60cm (Allard)..I will need 2 short right angled pipes


    diagram of pipework





    [/quote]

    ....3 months later finally past the thinking stage ....I'll see how the car likes living with this slightly more restricted airflow for a while before repositioning the old fan currently upfront to its new home behind the rad. Trimmed the new cowling which originally had the same perimeter profile as the cowling behind the rad with a jigsaw to fit snuggly one inside the other ... then bolted them together like this



    took the old fan and pwm controller unit off its old front mounted frame this afternoon and mounted it in the new adapted cowling (used some more bolts with spring washers to secure very firmly) behind the rad. im gonna run it like this for a week or two to make sure it doesnt overheat vibrate etc. was a bit worried it would vibrate too much as the old fan frame is actually cushioned with rubber grommets where its bolted to the car. but it runs smooth vibration free as before & aircon no change there either so looking good touch wood
    here are some photos...




    Last edited by 320de46m47; 07-16-2007 at 04:14 AM.

  2. #2
    Join Date
    Feb 2005
    Location
    Italy
    Posts
    44
    My Cars
    BMW 320D touring (136BHP)
    old intercooler

    new fabricated bracket painted black

    old intercooler out

    rubber tubes

    alloy extentions

    silicone bends

    there she is

    left side pipework

    sliced brake duct left side

    brake duct back in place

    same from the front

    right side with spliced brake duct ...forms part of the plastic structure and rigidity of the wheel arch so cannot be removed completely

    a side view

    top mounting

    undertray back on

    bumper back on

    from above

    finished

    and back home again

  3. #3
    Join Date
    Sep 2006
    Location
    Hopewell Junction, NY
    Posts
    63
    My Cars
    2002 BMW 325ci
    Looks really nice.
    2002 325ci

  4. #4
    Join Date
    Apr 2007
    Location
    South Africa, JHB
    Posts
    228
    My Cars
    mmm...
    too much work! but i like..

    ///bMpower

  5. #5
    Join Date
    Jun 2007
    Location
    Papillion, Nebraska
    Posts
    396
    My Cars
    e46 323i
    Thats Bad azz!!!!! I like alot, did you feel any gain in power?

  6. #6
    Join Date
    Nov 2006
    Location
    Moreno Valley, CA
    Posts
    14,175
    My Cars
    e46/325i e36/325i
    that is sweet. so you dont have the fan anymore right?
    RIP homie TehPandaShow: Loiue

  7. #7
    Join Date
    Feb 2005
    Location
    Italy
    Posts
    44
    My Cars
    BMW 320D touring (136BHP)
    yes increased performance and scope for more boost and fuelling
    lower thermal load on engine
    improved economy

    a/c fan has moved to the inside and is a puller now on the inside in a revised cowling

  8. #8
    Join Date
    Feb 2007
    Location
    NJ / NYC
    Posts
    2,175
    My Cars
    2011 135i M-Sport ///MT
    freaking nice!!!!!!!!!

  9. #9
    Join Date
    Apr 2007
    Location
    Northwest Arkansas
    Posts
    167
    My Cars
    2000 328i 2006 325i
    Way to cool. Great pics and stuff.
    2000 - 328i Black / Black with 120,000 miles

  10. #10
    Join Date
    Apr 2007
    Location
    Miami, Fl
    Posts
    2,537
    My Cars
    2003 325i ZSP, 1987 325i
    beautiful. awesome post
    Manual Sports Package l H&R Race Springs l Angel Eyes l 6k HID's l Clears l 5% tints l LED tails l M3 Trunk Lip Spoiler l Conforti's Cold Air Intake l CSL V2 l Vorsteiner Vented Hood

  11. #11
    Join Date
    Feb 2007
    Location
    Spocompton, Wa
    Posts
    7,069
    My Cars
    00 e46 (RIP) 03 IR ZHP
    Looks like a lot of hard work...im to lazy to take something like that on. Hell, im to lazy to even work at Taco Bell . No job for me.

  12. #12
    Join Date
    May 2007
    Location
    Newmarket, ON, Canada
    Posts
    24
    My Cars
    99 323i
    Nice work!
    99 323i

  13. #13
    Join Date
    Feb 2005
    Location
    Italy
    Posts
    44
    My Cars
    BMW 320D touring (136BHP)
    ive been asked to explain the cowling a bit more ....didnt make it very clear where it came from

    the 320d existing cowling is empty, just a large tube behind the rad. i noticed that the cowling from a 1.8i has the same outer perimeter shape as that in the 320d (check realoem.com) and it holds the same fan as that in the 320d, but behind the rad instead of in front. i wanted to keep the old cowling in situ but use the 1.8i cowling also (bought off ebay for not much) to hold the a/c fan. behind the rad it's doing the same job except it's now a puller instead of a pusher. i trimmed the 1.8i cowling round its edges to make it fit inside my 320d cowling and bolted them together... then it just drops in freeing up space at the front for the intercooler.
    1.8i fan here - http://i12.ebayimg.com/07/i/000/9d/a6/8cfa_1.JPG
    simon
    Last edited by 320de46m47; 07-19-2007 at 03:09 AM.

  14. #14
    Join Date
    Mar 2007
    Location
    Wharton, NJ
    Posts
    1,782
    My Cars
    '02 325Ci & '06 Raven R1
    thats wild, im impressed with the hooked up touring wagon...sweet

  15. #15
    Join Date
    Feb 2005
    Location
    Italy
    Posts
    44
    My Cars
    BMW 320D touring (136BHP)
    thanks for the nice comments guys!

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