Landcruiser VDJ 76/78/79 Series Front Mount Intercooler Kits

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sale

Landcruiser VDJ 76/78/79 Series Front Mount Intercooler Kits

from 1,600.00

There should be no doubt that these kits are the best option if you are chasing performance gains as our kit is fitted to a VDJ76 pumping out over 400rwhp.  Until we hear otherwise, thats the biggest numbers for a single turbo V8 cruiser on diesel (only).

On standard injectors, a late model dual cab has made 216rwkw with the assistance of our PDI front mount. In a single quick run you can do that with other intercoolers but our kits have shown they can repeat this many times due to the superior heat dissipation.

If all you want is reduced EGT for highway driving we have a very satisfied customer reporting a drop from 330degC to 280degC when compared to the leading aftermarket top mounted intercooler.  Your engine will be more spritely due to the cooler intake temperatures.

We have the Mk2 kits ready to go with improved flow and ease of fitment.

High Performance Diesel Intercooler front mount.  These provide the best intercooling for both high load and low speed work. Option of either 65 or 76mm thick core.

Tests we've done have shown the drop in post intercooler intake air temperature was 3x greater with the PDI intercooler than the best of the aftermarket top mount options currently available.  The intake air temperatures were cooler at all speeds.

We have the single entry option now available. This cleans up the engine bay and pipework is fully mandrel bent, without welding. EGR system functionality is removed for this option.

Mk3 kit pre-orders are being taken. Please contact us to get on the list - first in first served.

NOTE:Due to change in chassis on the latest revision of the single cab VDJ79 to get ANCAP rating our current model kit doesn't fit on drivers side as the steering box is in a different location.  If you have this setup please contact us and we can do a custom pipe.

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The factory placed the intercooler on the top of the engine since it met the low requirements they had to meet the standard power ratings on these engines. It also helped to keep production and assembly costs lower. It was not chosen as the most effective cooling solution.

We have installed a number of the PDI front mount kits with great results. When done on its own, the difference it makes to the performance is immediately detectable as the engine control system is adjusting performance based on inlet air temperature and the performance is more spirited under all conditions.  The cooler the weather the better your turbo engine performs and this is due to cooler intake temperatures.  Customers have reported the PDI intercooler is the best mod they have done for both regular driving and or chasing all out power.

By placing the core at the front you get best cooling available.  We've never heard of a top mounted radiator and thats because the cold air isn't there.  Testing, performed on a VDJ70 series and tuned to around 150rwkw showed that (at full load) the factory top mount was able to cool the pressurised inlet air charge from around 180-190degC down to 88degC.  The leading aftermarket top mount intercooler, further brought this temp down to 75degC - a 15% drop in maximum temperature.  On the same vehicle, our PDI front mount was tested and the temperature reached a maximum of 47degC, which is a 46% drop in temperature, being over 3x more effective than the best aftermarket upgraded top mounted intercooler available. The benefit of front mounting is even greater when power is increased as the boost is higher, more heat is radiated from the engine and the heat required to be removed increases.

Mk3 vs the Mk2 (and other front mount intercooler options).

The Mk3 core dimensions are 700x260x76. The Mk2 core is 570x300x76 (or 65mm) which means the new Mk3 core is around 10% larger. The Mk2 has proven itself to be highly effective and is on cruisers pushing 300rwkw.

We have designed the Mk3 core to be more effective as we are getting ready for the next level of power and torque. It has been made to have the maximum width (700mm) with custom end tanks that have 3” outlets that go through next to the headlights into the engine bay. The increased width gives the core better cooling capability as more fresh air is being pushed and drawn through for further improved cooling.

We previously used a more generic 300mm core height on the Mk2. The Mk2 uses fully cast end tanks with 2.5” outlets and to fit it needs to go lower at the front. We then run back along the top of the chassis rail back to the turbo. This means more clearance is required at the front and in some cases the bulbar needs cutting to allow for this to sit correctly.

The Mk3 has the reduced height (down to 260mm) with the core sitting above the horizontal crossmember instead of in front of it. This was done for a few reasons:

  1. The bottom of the Mk3 sits higher so that the fresh air is able to fully cover the core. With the PDI Mk2 300mm high core (or bigger by others) some of the core is in front of the 40mm high horizontal crossmember so there is basically no cooling through that part of the intercooler and anything below the crossmember has reduced cooling capability as it is behind the bulbar or bullbar plus any possible winch installation. Even though the Mk3 is 10% larger we expect the improved capability will at least 15%. The Mk3 eliminates areas of the core that are not being cooled so there will be no warm stream of boosted air being blended with the optimally cooled air so the overall result is improved.

  2. This allows the new Mk3 core to be closer to the condenser, which means there will be more effective pull from the engine cooling fan at low speed. Being so close it will be possible to make the seal even better with foam packing to further increase the draw through.

  3. No cutting to the bulbar will be required.

Our PDI kits do not interfere with the airbag sensors at the front so these kits can be installed on current model 70 series. No cutting of the structure needs to be done. The grill, lower panel and possibly the bulbar will need to adjusted to make room.

For the Mk2 the decision here is whether to go for the 65mm core or the 76mm heavy duty option.  The space at the front has always been limited on the 70 series and a few things need to be moved around to allow fitment, so before ordering the 76mm core it is worth getting you tape measure out and deciding if the bulbar installed is going to allow enough room.  Approximately 80mm is required for installing the 76mm core and 70mm to install the 65mm core and generally we find there is enough room for the larger unit. We have found that the large core would not fit behind an ARB winch bar in one case and it needed to be trimmed.  In other installs the intercooler has just enough clearance.

Our recommendations:

65mm core is better than all top mount options so you will not be disappointed.  

76mm core is recommended when planning high flow injectors as the extra boost you will run generates more heat and the thicker core has greater potential to dissipate the extra heat.

Once installed it clears up the top of the engine bay making access once again possible, rather than compressing lines and making inspection of the top of the engine more difficult.  The EGR system remains unmodified and flow continues to be routed through the twin throttle bodies. We have seen the six cylinder turbo diesel put down over 300rwkw through a single 2" throttle body so maintaining the use of the twin 2.5" throttle bodies will not in any way limit the power potential.

Kit includes

- brackets for mounting the intercooler with additional bolts

- intercooler

- stainless 2.5" and 3" pipework

- heavy duty silicon elbows and joiners

- wiring extensions for sensor relocation.

- quality Hi-Torque Breeze liner clamps

- installation guide.

To install you will need 

- normal spanners and sockets

- hammer and large adjustable spanner or bar to adjust support panel.

- metal snips or body saw for trimming lower painted panel.

- power tool to trim down the back of the grill for refitting.