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(Post Link) post #1 of 46 Old 03-02-09 Thread Starter
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1.9 jtd 16v fmic Q's

hi. i've been toying with the idea of fitting a front mount intercooler to our face lifted 1.9 16v jtd 156.

this is the intercooler i had in mind. will it be about the right size?

http://cgi.ebay.co.uk/ws/eBayISAPI.d...ayphotohosting

i had a measure up and it will fit behind the lover black mesh grill just.
i'm struggling to fine a route through to it for the hoses though.
i thought about fixing the 3 bolt fixings on the cooler into the metal beam that sits just behind the grill about half way up the bumper.
any info would be great.
many thanks
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Re: 1.9 jtd 16v fmic Q's

sure the 180mm tall one won't fit?
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(Post Link) post #3 of 46 Old 03-02-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

this one will be a very neat fit but after reading posts on the search i'm worried about the pipe lengths

this would be better but its not as pleasant or big

http://cgi.ebay.co.uk/Medium-65mm-2-...ayphotohosting
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Re: 1.9 jtd 16v fmic Q's

Get the intercooler, then remove both catalytic convertors and mount a free-flow back box...bmc-cda...

Then with a proper remap, you can run safe about 190hp.
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Re: 1.9 jtd 16v fmic Q's

the twin won't flow as well as the first one you mentioned.

if you can fit the 180mm, use that, greater cooling.

Use 2.25" alloy pipe, you can buy a set of mandrel bent pipes off ebay for 65quid or so, you will probably need to have a ring of alloy weld put on/near the end of the alloy pipes otherwise they will blow apart under boost loads.

you should be able to route the pipe over the battery. Install in a similar way (pipe routing) to kgb, he has some pics on here somewhere.

with the old intercooler gone, you should be able to fit the gsr intake pipe and filter
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Re: 1.9 jtd 16v fmic Q's

I'd really like to do this to the GT in the not to distant future.

Could someone post pics of the setup they have gone for and also parts used as in all honesty, I have no idea what I'm doing.

Cheers
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(Post Link) post #7 of 46 Old 04-02-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

could someone tell me what diameter pipe fits over the flow sensor near the airfilter. i need to know for a possible induction kit i can get my hands on.
many thanks adam
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Re: 1.9 jtd 16v fmic Q's

If i am not mistaken it is 70mm.
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Re: 1.9 jtd 16v fmic Q's

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could someone tell me what diameter pipe fits over the flow sensor near the airfilter. i need to know for a possible induction kit i can get my hands on.
many thanks adam
Drop CPH a PM, he has a pipe available for this car thats already to go.
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Re: 1.9 jtd 16v fmic Q's

So this pipe allows fitment of an aftermarket airfilter on the end without interfering with any airflow meausring device?

Last edited by typos1; 05-02-09 at 12:26.
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Re: 1.9 jtd 16v fmic Q's

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So this pipe allows fitment of an aftermarket airfilter on the end without interfering with any airflow meausring device?
yes, but again I think CPH can help you out with a decent filter to fit on the end.
The air mass sensor drops into the by itself if I am correct - best to drop him a line, he knows his stuff.
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(Post Link) post #12 of 46 Old 05-03-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

hi guys. just an update,
i have bought this intercooler and have had my front bumper off to see if it will fit. and the answer is yes just. i have had to move the power steering cooling pipe down a bit though. will get some pics done soon

just a quick question. how much will a pipe from the drivers side of the car to the inlet manifold affect performance??


http://cgi.ebay.co.uk/ws/eBayISAPI.d...m=300292700364
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Re: 1.9 jtd 16v fmic Q's

I would go the other way, from the turbo to the o/s fmic, then from the n/s of the fmic straight up over the battery (or to the side) to the intake.

If your doing a real smart job, then you could remove the turbo inlet housing (8bolts, but may require removing the turbo) and modify the exit so it points the other way, a decent machine/welding place will do it for about 30quid.
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Re: 1.9 jtd 16v fmic Q's

i had planned on turning the original outlet hose towards the front into the cooler. i'd love to do what you said but i'd want to do it to a spare turbo just incase
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Re: 1.9 jtd 16v fmic Q's

1 simple thing to remember with turbos and FMIC,s

Less pipework means less lag and more response.
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(Post Link) post #16 of 46 Old 06-03-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

some pics















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Re: 1.9 jtd 16v fmic Q's

Very nice work....

Now you can make some "really hard" remaping done on your car :-)
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(Post Link) post #18 of 46 Old 07-03-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

Whilst under the car i had a look at the turbo to see about cutting and re welding the outlet in the opposite direction but it would foul the exhaust down pipe. i need it to come straight out towards the front of the car idealy.
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Re: 1.9 jtd 16v fmic Q's

Looks sweet.

I imagine the same set up would fit the GT???
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Re: 1.9 jtd 16v fmic Q's

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Whilst under the car i had a look at the turbo to see about cutting and re welding the outlet in the opposite direction but it would foul the exhaust down pipe. i need it to come straight out towards the front of the car idealy.
Mine is just cut and set straight, then a 2 - 2.5" 90deg elbow sets it in the right direction towards the o/s.

The turbo housing rotates fully BTW.
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(Post Link) post #21 of 46 Old 08-03-09 Thread Starter
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Re: 1.9 jtd 16v fmic Q's

this is a pm i just wrote for someone so i thought i'd post it to help anyone else out.


hi mate. the biggest thing is the depth of the intercooler. my one is 65mm deep and i would say that it is the maximum that would fit behind the bumper.

http://cgi.ebay.co.uk/ws/eBayISAPI.d...category=72205

first thing to do is remove the plastic undertray, the inner wheel arches and the bumper. then there is a plastic cowel that sits around the radiators that will need removing and this wont be able to go back on.
i had to move the power steering cooler down and strapped it to the lower rad support bar.
the reccess in the bumper where the fog lights sit had to be slightly cut away to allow the power steering cooler pipes to clear. only need about an inch square cut out and this dosn't affect the strength and you cant see it when the fog light is back in.
the intercooler is mounted under the bumper crush bar, i just drilled 2 8mm holes through from the top and out through the bottom. i used a couple of M8 x 100mm bolts to hold it in place. may need cutting to exact length, depends on thread length on intercooler. also there is a bolt thats attatched to the underside of the crush bar that the powersteering cooler bolted to, left mine in place and just made sure that the top of the intercooler wasn't rubbing on it, if so just space it down a bit with some washers.
the bottom fixings of my intercooler sit almost the same height as the radiator support bar, i just cut some 20mm x 3mm flat bar that i had laying around to 100mm long. i bolted these to the bottom of the rad support bar with 1, 6mm bolt in each. i then pulled the intercooler as far forwards as it would go and drilled these two bars to bolt the bottom of the intercooler to.

as for piping i had to remove all of the standard airfilter and put a 90 deg piece of silicon hose on the intercooler outlets and sat them up at about 45 deg past the std radiator. on the drivers side there is an earth cable mounted to the chassis i had to undo and turn upwards. this allowed a small area for the silicon hose on this side. thats as far as i have got at the mo. the piping on the drivers side where the earth is will need to be squashed a little to make an oval shape. i.m planning on making a template for the piping from plastic water pipes then getting them made and bent into one continuous piece of aluminium pipe that goes from the turbo and the inlet manifold to the silicone hoses on the intercooler.

i have used the car since fitting the cooler and there seems to be no problems with airflow to the radiator,

if you need anymore info just ask and i'll try my best to answer

Adam
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is it possible to provide an A to Z newbie guide to get an FMIC fitted & airbox replaced?
which custom parts would be required to get this done?

thanks
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(Post Link) post #23 of 46 Old 26-09-11 Thread Starter
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well i finally done the pipe work today and got my fmic complete, and i've still got fog lights.










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Nice work
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Nice work. I had to loose my fog lights to do mine. bit gutted now I seen yours
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