HDJ78 / HDJ79 / HZJ75 / HZJ79 Front Mount Intercooler Kit

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HDJ78 / HDJ79 / HZJ75 / HZJ79 Front Mount Intercooler Kit

from 1,800.00

These are the neatest and most effective intercooler kits to suit your 75 or 79 series cruiser.

The PDI intercooler for the 79 series sits directly behind the factory grill for maximum cooling potential and will not interfere with other installed items such as lights or a winch.  This is possible with the relocation of air conditioner piping and the drier to the engine bay. 

Long term testing has shown this to be highly effective for the inlet air temperatures and for the function of the air conditioner itself with no impact on the radiators ability to keep the engine cool. 

The cores are 600mm x 240mm, which fills the space available at the front. Our front mount kit cooling capability is greater than all other kits we have tested so the improvements in torque and power will exceed other results. The difference in some cases is significant.  See below for some of the results.

Once fitted are a zero maintenance setup, and still allow access into the engine bay for any maintenance or inspection.

For those who have 75 series cruisers with the narrow grill or others wanting to update to a RV chrome grill, we have some in stock and can be sold either in standard form for $120 plus shipping or modified (for the intercooler) for $350. A nice way to make the front of your cruiser look great.

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Our test HDJ79 cruiser is putting down 287rwkw on heavy mud tyres that suck an additional 15rwkw, so we have a kit that supports +300rwkw.  This allows us to get some high load testing done and also be assured that not many are going to push it harder than we do - hopefully by then we will be pushing it harder too.

The power output for the 1HDFTE in the ute and troopy was set to be 122kW (at the engine), down from 151kW in the 100 series with the factory fitted intercooler.

We have managed to fit a 600x240x65mm core behind the factory grill (with a bit of slimming to the plastic), which for many who have considered the custom install to be impossible. The pipework is also 2 1/2” stainless steel for improved flow and durability. 

Initial testing of the system was with an upgraded Gturbo Badboy turbo, tuning module, Safari ARMax snorkel and running standard injectors and standard airbox.  Dyno testing with this configuration has resulted in a max power of 186.4kW at the wheels with a low 20psi boost.  We also managed to achieve 18psi at 1550rpm with maximum torque of 668Nm at (only) 1850rpm. There is no doubt this is has to be one of the best combinations for a "mildly modified" 1HDFTE that boasts only 122kW at the engine (100rwkw) in factory form.

Our next step was to install +30% injectors. There is a step change in performance with this upgrade and needs a retune.  With a few changes we managed to get 246rwkw (330hp at the wheels) and 900nm so an excellent result.

The current setup is running +70% injectors and has 287rwkw and almost 1000nm. We are calling it a safe +300rwkw as the tyres suck a proven 15rwkw.

To make space for the intercooler core, the air conditioner piping has to be rerouted.  The components to do this are included in the kit and the task is simple enough.  Spacers are provided to space the radiator back at the top.  Then the condenser has a few spacers and longer bolts to allow that to also be pushed back so that nothing touches.  The condenser stays in place and flexible lines take care of the rest of the relocating. Initial testing on two different cruisers resulted in the fitter doing the regassing comment on how well the system was performing.  With the installation of the core up front it continues to work really well - on a hot day it is the place to be.

With the ambient temperature 33-37deg a heavy tandem axle trailer was hitched up to increase load.

                                                     Post turbo inlet             Post intercooler inlet temperatures

Normal around town driving            50-150degC     42-46degC

Highway normal driving (towing)    90-160degC                     48-52degC

Max load up long hill                         180degC                           60degC

Under full load thats 36% more air going into the engine, which will result in a significantly improved EGT with the same fuel or add more fuel to make even more power. For those running standard injectors this is an excellent improvement. All these results were using a 500mm wide core.

We have done some more testing of the current 600mm wide core now that we can apply more load.

When working hard the turbo outlet temp was pushed to 260degC and post intercooler temps were down to 70degC - a 190degC reduction.  The results below show how effective the PDI front mount is compared to top mounted configuration.

Compare this to one of the mid size current top mount setups that had turbo outlet temp of 130degC and post intercooler temp of 90degC - a 40degC reduction.  We have tested the largest top mount offering and with around 150rwkw the post turbo temp was up to 190degC and the post intercooler temp was 75degC - a 115degC reduction.

If your preference is to get rid of the factory intake crossover pipe (for the EGR system) a forward facing alloy adapter off the intake manifold can be supplied.