HELP! Fitting 110 intercooler system to 90 HDi

[sockpuppet]

Hi there

As the title says, or some of you may know, I have a 406 hdi 90 (mk2) with no intercooler. i have the intercooler from a 110, and SOME piping. i dont know what it does or where it goes, but i bought "406 110 intercooler pipes" from ebay, and theyre in my boot, getting dirt on my various things.

will the 110 intercooler pipes and the intercooler be enough bits to fit it to my 90, or will I need some other stuff, as part of something called "EGR setup" (im quoting because i dont know what that is, or if its relevant - hi, im a noob to mechanics)

there's THIS that i found on ebay, called an intercooler pipe hose, not sure if thats needed...

http://cgi.ebay.co.uk/PEUGEOT-406-HDI-M ... 335b809989

Please offer any advice, as it appears that im a complete lemon who didnt do his research!

[puggy]

looks like the bottom pipe from the intercooler , joins onto the plastic one running
under the engine .

[sockpuppet]

is that the only pipe that i should need?

[steve_earwig]

I put the diagrams for both set ups on the other thread here. On each there's two different sets of plumbing, with the doser and without, if you have one I'm not sure if the engine management would be happy without it, so you may need to get the appropriate set up, including the doser as it has a different part number (or, if you have one, you could try disconnecting it to see if you get any complaints.)

That pipe you're looking at on evilbay looks like #3 on the DW10ATED diagram.

[sockpuppet]

ahh yes, thanks for those diagrams.

still not really sure what im doing though, but ive just paid £25 for the pipes so hopefully its everything i need for my car. if its not, i might have a cry, because my student loan isnt supposed to be spent this way!

[FlySpeck]

you need to figure out the path from the turbo outlet to the engine inlet, and plumb the intercooler to sit between them.

air drawn in and compressed by the turbo gains heat from being compressed, so the intercooler allows the temperature to be reduced in the intake charge without loss of pressure (well there must be a small loss when the air is cooled again (Gas Laws) but constant flow from the turbine covers it up)

Really you can fit the IC anywhere as long as its connected between compressor and inlet tract, but remember that too long a path will increase turbine lag, as the IC and all pipework has to be pressurised before the engine receives any boost.

[jasper5]

The intercooler is usually fitted next to, or in front of the radiator for maximum cooling of the air before in enters the engine so that it is as dense as possible for the best combustion.There are exceptions such as my old Nissan Terrano which had the intercooler on top of the engine with a scoop cut out of the bonnet to collect the air and direct it into the intercooler and therefore directly into the intake manifold.