PDI Front Mount Intercooler Kit suit Landcruiser 200 Series

PDI currently offer 2 options:

Mk2 Standard is 610x320x76mm. This design is slightly bigger and requires room to run the pipe across the front to get air from the passenger side turbo into the intercooler.

Mk2 Slimline is 610x285x76mm.  The core is slightly smaller vertically so we can do away with the pipe across the front and give room for the current range of bull-bars with winches.

Single Entry vs Dual Entry 

Both the single entry and dual entry kits use the same intercooler and identical hot side piping to the turbo. The difference lies in the cold side piping configuration.

From factory, the engine uses two throttle bodies (butterflies) facing left and right, feeding into the top mounted intercooler.

• Dual Entry Kit:
  

  The Dual Entry Kit retains the factory style intake layout by connecting to both throttle bodies, with the intercooler outlet split to feed each side while maintaining the original intake path and OEM configuration.

  The design also retains the factory butterfly throttle valves within the system, ensuring smooth engine shut down and maintaining the original safety and drivability functions. For vehicles fitted with automatic transmissions, this also preserves the ability to shut the engine down in the unlikely event of a runaway condition caused by  running on its own fumes, a low probability but high risk scenario.

• Single Entry Kit:
  Removes the throttle bodies and their mounting section entirely. This section also contains the EGR (exhaust gas recirculation) feed, so switching to single entry requires blocking the EGR port with a plate, preventing exhaust gases from entering the intake.The single entry design offers a cleaner installation and improved throttle response.

200 Series post 2013 
The throttle bodies must remain plugged in electronically to avoid fault codes and power derating. A bracket is supplied to mount them off to the side.

Why Front Mount Beats Top Mount

Testing, performed on a VDJ70 series, running the same engine and intercooler as the 200 series and tuned to around 150rwkw (similar to the 200 series) 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. A quality aftermarket top mount further brought this temp down to 75deg 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 a quality aftermarket upgraded top mounted intercooler. The benefit of front mounting is even greater with further power increases as the boost is higher and the heat to be removed increases.

Top mount intercoolers are popular due to ease of installation and bonnet scoop aesthetics but they simply can’t match the performance of a properly designed front mount.

A front mount intercooler delivers:

• Better cooling at both low and high speeds
• Consistent airflow regardless of driving conditions
• Lower intake temps and improved engine efficiency

With the release in 2019 of the Mk2 design the results have been amazing, making it a critical ingredient, if pushing 400hp at the wheels or doing heavy towing. In fact the first upgraded turbos for the 200 series were not developed until we had released a front mount kit.

EGT Gauge.

If you plan to install an EGT probe, we recommend doing this into the dump pipe after the turbo. Recently we have decided to stock an EGT probe system that uses a Class A probe with 2m long lead and digital display making it easy to read and mount. We have another option in green that has a smaller thread for mounting into intake air temps if you wish to see how you system is performing. These can be purchased HERE

Optional Transmission Cooling Upgrade

For automatic vehicles, PDI offers a high BTU transmission cooler upgrade, mounted neatly in front of the intercooler using custom brackets. This ensures your transmission stays protected under heavy load without compromising intercooler performance.

To confirm the clearance for the Std model PDI intercooler you will need 90mm in front of the lower radiator support. Additionally you will need 145mm (towards drivers side in RHD vehicle) from the 8mm mounting bolt to ensure clearance around the bullbar mount.

The 200 series Landcruiser is a solid vehicle with good power and torque, suitable for towing heavy loads in comfort. When considering performance upgrades, the first step in performance should be an ECU reflash, which is an effective and simple solution where boost and fuel are increased above standard both of these will result in an increase in inlet air temperature.

If you wish to maintain the thermo fan at the front then 2 lugs are on the passenger side of the intercooler to assist in the mounting of a Spal VA10-AP10/C-61S 12V. This is on the cold side of the intercooler so will still allow cool air to reach the condenser under most driving conditions. We suggest not running any other brand of thermo fan, regardless of rating.