Intercooler w202 - Printable Version +- STD (https://www.superturbodiesel.com/std) +-- Forum: Tuning (https://www.superturbodiesel.com/std/forumdisplay.php?fid=6) +--- Forum: Engine (https://www.superturbodiesel.com/std/forumdisplay.php?fid=7) +--- Thread: Intercooler w202 (/showthread.php?tid=6303)

Intercooler w202 - Booster - 03-03-2015 Ok, so I got over excited and ordered an intercooler that seems far too big. I have two options  1: Could I move the Engine radiator forward and place the intercooler behind? OR would this not provide enough air/have heatsoak? I Could put some electric fans on the front to aid airflow? 2: Sell the intercooler and buy a more sensible size one?  RE: Intercooler w202 - Hario' - 03-03-2015 ? RE: Intercooler w202 - erx - 03-03-2015 Intercooler behind the radiator is definitely not the way you want to do it, it would be even worse than without cooler. That way the air will be heated not cooled. RE: Intercooler w202 - TurboTim - 03-03-2015 Can you cut the bumber support? RE: Intercooler w202 - EDH_Performance - 03-03-2015 Fit like a charm in my w202: RE: Intercooler w202 - Booster - 03-03-2015 My intercooler is huge, so fitment wasn't easy however I have done it. Hario : You have cut the bumper support out? And made a new one? If so thats what I did also. ERX: Yes I figured that would be the case just didn't want to wait around sending the cooler back.... was being lazy EDH: Your cooler is much smaller than the one I have, Its all sorted now by removing the support bar at the base. RE: Intercooler w202 - Booster - 03-03-2015 Could you post pictures of how your pipe work went EDH and hario? Mine is 3" and finding it hard to find a good pipe layout that doesn't rub on things? RE: Intercooler w202 - Hario' - 03-04-2015 I cut out the radiator supports and made my own further outward from stainless, you can see in my photo. C-section stainless supprts. And also cut off the tow hook eye. This was to allow the pipes to exit directly sideways as the OEM IC has complicated plastic pipes to clear eveerything. I have now cut the inner face of the front X-member for more clearance and cut off the lower bumper mounts to allow the intercooler / radiator to sit forwards because I have fitted an OM606. Just drill spot welds then hacksaw each end vertically and it falls out. you will have issues with the 3" pipes fitting the auto-box cooler pipes in the radiator end tank assuming you have 722.6 Beers, H. RE: Intercooler w202 - Booster - 03-04-2015 I also had to cut the front tow bar, I'm worried about the 3" as it fits but touches the body in a number of places, think it might rub through? RE: Intercooler w202 - Hario' - 03-04-2015 Mine rubs in a few places, I've just made sure it's not 'pressing' against anything RE: Intercooler w202 - Booster - 03-04-2015 Its hard to describe the route that my pipes have taken.... there is a triangle cut out just behind the headlights and my pipes go up through that.... the gap can only be 3.25" if that, might put some silicone around them for it to rub against.? RE: Intercooler w202 - Hario' - 04-02-2015 Thinking about that, maybe get some 1/2" silicone hose and cut a slit down it, and use that as gromet material to slide over and around the metal edge of the triangluar hole? Rather than siliconing the boost hose? RE: Intercooler w202 - Booster - 04-02-2015 I used some spare silicone I had like you said. To be fair I have done a few miles in it and it hasn't rubbed at all... I think it's all sorted!