TTE Intercooler Upgrade


Firstly I have to say a big thank you to Rabster (for the use of his warehouse),
secondly for the extra pair of hands, and thirdly his head for bouncing ideas off.
Together we had a very successful day

The TTE intercooler as supplied with the TTE Supercharger has been deemed by many
as the real limiting factor in gaining more horsepower from a S/C IS200.
Katana & Pro-Lex intercoolers have been fitted to some LOC members cars, but they
have required chunks of metal being removed from the Crash Bar (amongst other mods required ).
I wanted a larger intercooler, but really wasn't eager to have all that hassle involved

I researched the exact dimensions of the original TTE Intercooler (sorry meant to say I asked Stav )
then measured the available space, and came up with a 3D shape I required the intercooler to be.
After some considerable worldwide internet searching, I actually found what I was looking for
right here in the UK on E-Bay

Just one slight hitch, it was about 1 inch wider than the available (guestemated) room. As I hadn't
taken off the front bumper to measure, it was going to be a crossed fingers affair, but I had enlarged
intercooler's size in width by about 3 inches, and in height by 3 inches, but with a very tiny couple
of mm depth. It did however have one major benifit, it had a cooling volume 244% larger than the
TTE Intercooler it was replacing
In fact 2 major benifits, secondly it cost just £82.50 including P+P

First off the Sport Grill was removed


Turn the steering wheel to full lock so you can see the front edge of the inner front arch liner
Then the 2 inner arch retaining pins were removed


Reaching inside the arch liner, the Fog Lights were disconnected,
then the Bumper Securing Bolt was removed


The same was completed on the other side, then the bumper was supported at both ends and gently pulled away.
When it was free, the last step is to disconnect the Headlamp Washer Hose from the washer bottle pump assembly.

Bumper Removed


Then the polystyrene crash bar pads were removed, and the new Intercooler placed for comparison
under the existing TTE Intercooler



The TTE Intercooler was removed, and the new Intercooler was connected to the hoses
for a 1st Test Fitting (just to see what we were up against).

After first inspection things didn't look good. No matter what we tried, it looked like the inner curvature of
the Crash Bar was going to touch the intercooler at both ends. I didn't remember it being curved when the
Supercharger was fitted but it obviously was

I really was unwilling to cut into the Crash Bar so much head scratching ensued.
After much deliberation, it was jointly decided to remove some metal from the bar in the middle in front of the
Air Conditioning Radiator.We then cut a notch in this bar, that the Power Steering 'cooler' could be attached to.
(this was originally moved for the fitment o the TTE Intercooler)

Cut & Painted (to avoid rust)


Power Steering Cooler's new home


With that job done, we could losely fit the new Intercooler with the bracket



Then the un-cut Crash Bar was refitted


Oh boy thats a tight fit (expecially at the ends where the crash bar curves)


Rather than letting metal psssibly rub against metal, some sticky foam pads (in double thicknesses)
were applied to allow a bit of give, where the intercooler/crash bar met.


Whilst I had the bumper off, I had an idea of what to do with the Lightbrows I've had since last September
(& never got around to deciding wether they were a good thing or bad )


then add a bit of power


Time to refit the bumper and take a peek



Oh yeah happy with that

P.S no copycat

The results........

The ECU has been re-set, initial impressions over the first few miles were slightly dissapointing, little if all difference,
but the more miles I drove on the way home,the better/smoother it seemed to be running. It does seem to pull stronger
over 4,000rpm than before, but is indiccating slightly less peak boost to the pillar pod gauges.
Just under 0.5 bar compared to just over on the TTE Intercooler



Stav suggested it may be the same output as before, but the larger interior volume of the new intercooler (244%) for the same
output from the Supercharger = less indicated boost ?? I am guessing that is then counteracted by the lower intake
temperature and still equals gains over before. I'm no engineer as you can probably tell.

I am making no claims about actual horsepower gains, it's just a seat of the pants feel that it is pulling harder
at about 4,000rpm upwards. It could well be a placebo effect. I'll have to give it at least 100 miles more or so
as the ECU has been re-set, and it will take some time to re-learn, and once this is done, I can re-evalute my
estimations as to how the bigger intercooler has affected horsepower/torque.



Cheers again to Rabster for all your help mate

the lit up intercooler looks wicked and totally original(i think) never seen it before,all we need now is a pic at night to really appreciate it.

good job there woz

everyone assumes a larger intercooler will be instantly better performance wise.

however the key factor is pressure drop, all intercoolers are not the same, some are good, some are bad its that simple, and its all down to correct sizing for the application intended, its all very well saying you have XX amount more surface area, but its all hidden....DIRECTLY behind the crash bar, not in any usefull airflow

as you have stated, the overall boost has dropped (due to pressure drop )

consider this.....TTE are a multi-million pound subsidery dealing with Toyota's motorsport concerns, with some of the worlds best automotive designers working for them, im sure they had calculated that the intercooler provided was capable of working fine with the superchargers nominal output.

However, a slightly larger intercooler, with adequate shielding and in a good path of cool air WILL see an increase, but nominal. further modifications will be required.

This is not a dig, just want to clarify that your expected outcome is not easily attainable by just putting on a generic intercooler from the internet

have to admit though, it all looks very good

Lokks good mate. and i am inpressed by the intercooler lighting up.

Well done.

Stav

out of interest what effect would a nitrous or water spray have on the intercooler as a friend has it fitted on his subaru

(i was told it increases boost?)

excellent write up but you didnt put down the angle grinder sob sob that was the fun bit lol

considering the time it took to do the whole thing was around 6 hours i dont think thats to bad infact i think thats bloody good

hmmm no copycats does that include me 2 lol

I unserstand where you are coming from, but the pictures dont back this up, only approx 20mm of the new intercooler is hidden behind the bar.

Compare the original vs new


where there is much more on view (width, height and also depth)and getting good air flow.


Excuse the angle as it isn't low enough to compare directly like for like, (and the top visible cooling fin is hidden beacuse of this angle)
but there are 8 cooling rows now on show to airflow, out of a maximum total of 9. Not only is the new intercooler cooling area higher,
but it is also wider, also where the original intercooler's finned depth is 51mm (of a total depth of 63mm including the end bars), the new
intercoolers cooling fins are deeper covering the full depth of the cooler (65mm).

Cheers Stav for the photo

TTE Intercooler
Core Size
430 x 115 x 51
Inlet/Outlet Diameter 54mm

New Intercooler
Core size
531 x 180 x 63
(180 - 20 = 160mm high of unrestricted airflow)

Inlet/Outlet Diameter 56mm


I believe this will be the case, but like I said above, I have no yardstick to measure against other than my own experience in the car,
& no dyno reports as the car is an Auto (the only drawback with the Auto IS200 IMO)


no worries Matt, I totally respect your opinion


Thanks
I do keep exterior mods to the car to a subtle minimum, and here the lights are wired independantly from
the cars lights with a switch fed from an ignition live, so they will only go on when I want them too. I was
(after hosting the pictures and writing the thread) too tired to go out for a drive last night & take some pictures
in the dark.

Tonight however ............

I will also try to do some more miles and make observations as to how the car is running.
Cheers guys for the comments

need to loose that number plate, thats restricting and disrupting flow

Rabster is a dangerous man with an angle grinder
Total 6 hours including food/drink breaks, internet surfing (addicted to LOC) and plently idea swapping too
You can copy mate as it was shared thinking all day long


I mentioned that to Rabster yesterday

When I get around to putting my private reg on, the new plates will be moved slightly to accomodate more airflow

Saw this up close last night and its impressive!! Well done to you both!

what you want is one of those stick on plates just your number plate on VINYL stick it straight to the bumper then no 1 can nick it plus NO restrictions lol

ermm no

I take it all your good ideas came along yesterday

yeah they all fell out during the angle grind sessions lol

Well done on the bravery side guys Looks like you have done a good job


Though I hate to, but I must say (& I know its all down to personal taste ) those led's look like a max power meets knight rider affair...sorry Click to view attachment

lol i can just imagine the noise the knight rider car makes as wozzas driving round soho on his way to work obviously

.....and not forgetting the KITT voice on the satnav commands

The intercooler looks good and lower down than original?? which would help airflow.

The LEDs are a bit rice burner for me too, especially if they light up the road when they are on at night.

Re: bravery
I thought that if we get into trouble Rabster (Andrew) knows what he is doing so we should be alright
The problem is he thought the same about me & he didn't care as it isn't his car


oh my

1. they aren't on all the time, and will be used spariingly (I have a very discrete switch)
2. they aren't Blue, Green, or Red Neons
3. no silly graphics all over the car
4. they don't flash/strobe/sequence to the music
5. it's a Lexus not a Saxo/Scooby/Evo
6. no handbrake turns or donuts (well maybe a few chocolate ones )
7. as a passer by you wouldn't know they were there unless I switched them on

I did buy them ages ago last year (for about £13) and had to use them for something other than as "Firelighters" (sorry couldn't resist that )

Could'nt you of made a bracket for the IC to sit lower than the crash panel as this would aid air flow, failing that what about moving the number plate backing plate a little higher.

Nice job BTW

I'll hold comment on the LED's as your a nice guy.

I have Mr.T on my PDA with TomTom

btw the way the lights are set up, they point backwards away from the bumper (& the road) and purely
shine towards the I/C so you see only reflected white light. There is a small lip on the edge of the mesh.


Also no-one has spotted the "other mod"

i know i think we got away with that one for now lol wait for it people will be hunting through the pics looking for it lol

The IC now has only space about 8-10mm underneath it before the bumper wouldn't go back on. It's very tight there.
The number plate surround may well get modified/removed when I get around to putting the private reg on, so I can
move the plate higher.

As for the LED's, you work in an industry where most Trucks have hundreds of lights on them on the cab superflous to requirements.
I also reserve comment as you are a nice guy

ok I'll let you off ....for now

@ firelighters

Make the LEDs red and get one of these..........Knight Rider Satnav

Can't help thinking those LEDs will look weird lighting up just that one section of the bumper........will wait to see what it looks like in the flesh before passing judgement though

What's the other mod btw? The anticipation is killing me

Can only see something round sat above the offside end of the intercooler??

Is it the Front view Camera Wozza????

Stav

It's not one section of the bumper, it is the intercooler that will be illuminated, the top section behind the sports grille has nothing to
reflect the light (black aircon rad) and trust me will look very nice at night, plus remember I won't be driving around all the time at
night with this lit up. It will be used sparingly.....this pic may give a better idea


as for the other mod, well done Tigerfish & Stav
It's a big one, but was free (how many times can you say that and get away with it ?!?!?!)

No no no...they are needed coz you'll be surprised how many car drivers dont see trailers or cabs, it gives a perspective on height/width.

Found you on the web

Yeah i remeber, but you've obviously forgotten that you was with me......on the back of the trailer dressed up in red

Some cars have water spray system for the intercooler, controlled from a switch on the dash
like the IS200's headlamp washers. The theory is the water spray cools the intercooler, which
further reduces the intake air temperature, and cool intake air is what you want to make more
horsepower. The nitrous is injected into the cylinders and increases horsepower in very short spurts,
(too much for too long equals melted pistons).

Pete ask wozza about the 32 tonner that he pulled out of in front off when in france

broad daylight as well

Touche Barrie, Touche !

Explain Wozza.....thats the reason for the under I/C lights.....so you can be seen.

indeedy

Ahhh so thats what you were upto when you asked me for instructions on how to take the bumper off? Looking good matey

new i/c looks nice wozza. thought the standard s/c setup pushes max of 0.4 bar boost?? urs is at 0.5 though....

full credit to u for attempting the change over, u'll have to let us know if the AFR is affected, as there is much talk it will be as with the standard i/c its on the edge of leanness.

not sure on those lights though mate, but its certainly different.

rob

I love the pimped out lights. I'm looking into getting 6 foot long LED strips for the Type R..haha!

0.3 bar or 4psi is the max for the TTE setup, but because Woz's is an auto and the way it changes gear, it overboosts during changes.

Stav

Looks nice. The LEDs are a very original idea, I'd like to see the effect in the flesh.
BTW my crash bar has not been cut, there is enough room for the Katana to fit.

very original mate nice job

this thread is useless without a dyno graph

Wozza - just say your car has 300bhp Because you say it, we believe it (I feel the Wozza Etch A Sketch making an appearence )

Only 100bhp from them LED's?

I thought they gave more!

well i recon the LED = +100bhp
the car has lost weight ANGLE GRIND ME UP
i recon the camera gotta make it faster so not gonna over speculate but if a single resistir chip can give a +25bhp i recon the camera circuit getting to at least a +plus 80bhp

so its well over the 300bhp mark now he he

Thanks guys some nice pics for you to follow.
Apologies Yemgi, I'm sure I saw on LOC a TDi involved thread they had to cut a chunk out of the crash bar on an IS200 to fit the Katana.

Anyways as requested some night-time pictures. I found it difficult getting a true picture however as it either seemed to be over exposed
and the lights are actually too bright, or under exposed with realistic lighting but the car comes out duller than it should be....
To give you a true idea how bright the light from the LED's on the intercooler actually is, I only had my sidelights on, and they are of similar
brightnes to the I/C LEDs........if the sidelights and I/C lights look too bright, that is only a photographic effect.





I know opinions will differ, but I think they look awesome with the top picture being a truer representation, but they will still only be used
sparingly maybe pulling into a meet at night etc...

With PCIronmike's help some video was taken too of the car showing the illuminated I/C at night, & the Pulsing Brake Lights given to me by Gord.



Also with over 150 miles in the car today and the ECU learning, I am pleased to say the missing peak boost is slowly returning....

yesterdays peak boost


peak boost tonight


I know it's not much fro 0.45 bar to 0.5 bar, but it is a definate improvement since yesterday.

Dude Love the LED's, that is like a must have......


sorry for keeping ringing mate. guss how far i got with it.....no where...... lol

As its a driven component the pressure will be the same at the same RPM regardless of the ECU learning or being reset.

Wozza - at what RPM are you getting .5 or close to .5 bar pressure? If its possible can u tell me the pressure at 5K RPM?

Thanks rob