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Intercooler Conversion for 1.8TD
Intercooler Conversion For Mondeo 1.8TD
Here's a diagram with all parts labelled. You can get the samco hoses and jubilee clips from www.demon-tweeks.com and the mikalor hose clamps from www.powerengineering.co.uk/mikalor
Before Starting
On a Mk2 Mondeo, it will need a small piece of the bonnet bracing cut out above where the RS-turbo pipe sits. You will also need a bleed valve on the turbo, or the boost will be way too high. You will need to turn up the fuelling on the fuel pump so that the car doesn't run too lean. You will need a boost guage to set the turbo boost level correctly. The bonnet sound deadening will need to be removed completely, as will the engine undershielding and black plastic panel under the front bumper.
Here We Go
The intercooler fixes to 2 black plastic brackets with holes in them that stick out of the bottom of the radiator. I don't think this could be done on a car with air conditioning.
Please note - my car has an alloy dump valve box made for where the existing black U-pipe is on the end of the intercooler
Top of Engine - Alloy Dump Box
Finished Pipework - Top of Engine
It's a very worthwhile modification and makes the 1.8TD much quicker than standard. It's virtually the same setup as on a modern 2.0TDCi mondeo. Pipe lengths, etc, all work out about the same. Also, there is no turbo lag (some people thought that there would be because of the long pipes, but as we know the 2.0TDCi also has these long pipes and that has no lag whatsoever). The standard top-mount position of the intercooler on a 1.8TD is pretty poor, and gets very hot through heatsoak in the summer months. This "FMIC" eliminates this problem and makes the overall power curve much better.
Submitted by percybigun