At PDI we ensure our products are optimally designed for max efficiency. This means big core options and suitably sized and configured piping kits. Our 100 series intercoolers are the largest we can fit in the front of the 100/105 between the headlights – while some might argue that a larger cooler can be placed out the front, we have seen significant benefits for the cooler being close to the condenser for max draw through from the main engine fan. Placing a core further away requires the need to consider the addition of cooling fans, since there will be no draw from behind and typically a bullbar is placed. In addition to designing the pipes so they can use less joiners and simple silicon, that can be easily sourced we have chosen to use 2.5” piping to improve flow characteristics.
We incorporate a fitting in the base of the drivers side end tank, being the lowest point in the system, for draining of any oil that may potentially build up.
If you have a late model 100 series, you may note that Toyota have added a small black “vacuum hose” from behind the intake which disappears into the insulation around the intercooler piping. The purpose for this hose is to push any oil in the lowest part of the plumbing, back into the intake and prevent it to build up – this works due to the pressure differential to the other side of the butterfly. With a PDI intercooler installation, we typically just block this hose, but it can be connected to the port at the bottom of the intercooler with an extended hose and barbed fitting.
To cater for different airbox and turbo setups PDI have 5 different hot side pipes so we can provide the best fitment to your install – we will exchange these at $100 (plus any silicon or clamps you may need) for those who are going to be doing upgrades later. Also available is the crossover delete to clean up the top of the engine. That adapter itself is the best designed for the FTE and provides mounting for the MAP sensor and sensor filter.
If you have an auto we provide the largest transmission cooler we can fit there and place it our front so that the transmission gets optimal cooling.
We had a customer come in recently to resolve ongoing issues with hoses blowing off (for a competitors kit). A few things we noted were:
They had been running smaller pipes for hot and cold side – this is OK for std turbo configurations.
PDI have one pipe on hot side and 2 on the cold side (to allow for engine movement and make shipping easier). The other kit had 2 pipes on hot side and 3 on the cold side. This means 7 joiners, instead of 5.
PDI use much higher quality (high torque, liner style) clamps in all our kits.
The joiners were too short and clamps were incorrectly placed to ensure trouble free motoring.
The oil suction pipe, as described above conveniently went into the closest point in the hot side piping. Just in case you missed the purpose of this hose, it should be going to the lowest point in the intercooler system.
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