R2.8 cooling and intercooler system

Francois1

Member
I have a Cooling/intercooler system question for R2.8 owners. As I wait for my new engine to arrive, I am looking to pre-order parts for other subsystems and plan for the upcoming transplant (it's going into a 1986 110 SW, 3.5L V8). Searching through the posts here it seems that most people are going with custom radiator/intercooler set ups.
-Has anyone considered using a stock rad/intercooler package from a 200tdi? Do you see any reason why this wouldn't work with the R2.8?
-Has anyone used a water/air intercooler system?
-Any recommendations on a specific rad/intercooler combo?
Thanks!
 

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Napalm00

Technical Excellence Contributor
Has somebody who's fighting temperature issues on his modified 2.8 L 200 TDI . I wouldn't use the small TDI radiator. Smaller than the radiator in my 1999 Miata and just not up to the task.

In the 2.8 forum there are links to the off the shelf custom made units
 

13diamonds

Active member

or


or use a stock TD5/PUMA Setup.
 

MountainD

Technical Excellence Contributor
Order all parts, whatever they are EARLY. Lead times are getting severe. My intercooler is still 8 weeks out. My aluminum oil pan from Cummins has a 3 month production lead time…. I have already received everything else, much ordered in April
 

dkemm

Well-known member
I currently have 3 FMIC, FB603 - downside is side tubes. Likely going with cosworth 500rs fmic - got two - shipping situation, but back facing ports,
Using a griffin radiator
 

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dkemm

Well-known member
If you want one of them
Let me know, was getting ready to ship back rs500 unit, not sure if I can return other one as I have had for a bit
 

KGH

Well-known member
According to Chad at QD, there is an outfit out west using 200Tdi rad and intercooler package. I would assume Alli full width.

Doug’s package (lol) seems up to the task.
 

MountainD

Technical Excellence Contributor
Not so sure about the 200TDI package for places like Colorado with less thermal density in the air and strong hills. Maybe for the flat land. I would never do it--nothing ruins your day like excessive heat...
 

TheOneTen

New member
The installation manual clearly indicates the sq in of intercooler and radiator space that should be leveraged for the motor. The 200/300tdi setup is just not up to the task.

The TD5 setup that Doug has been using is pretty spot on.

Also, depending on your transfer case, you really want to make sure you're keeping the engine in the right RPM range. I had a 1.4 transfer case and at highway speeds, the motor was simply wound up too high (3000ish RPM) and it simply ran hot. Switched to a fancy 1.1 transfer case and my 5th gear (which already had the taller gear) is now basically an overdrive gear on the highway. Cool to the touch.
 

MountainD

Technical Excellence Contributor
Which is what I’m planning on, argon backfed stainless mig. Still have a tank of pure argon, just for stainless and aluminum. So wish I had a tig right now…

and great job. That’s a lot of hard work right there…
 

MountainD

Technical Excellence Contributor
Where you have your muffler, I was going to try and put my DOC, if it would work heat wise for it to do it’s catalytic thing (Emissions in my area test/inspect for it). Do you think it could cram in there? I’m not sure any further downstream would be acceptable to them… gonna Be tight on the frame rail….
 

dkemm

Well-known member
Where you have your muffler, I was going to try and put my DOC, if it would work heat wise for it to do it’s catalytic thing (Emissions in my area test/inspect for it). Do you think it could cram in there? I’m not sure any further downstream would be acceptable to them… gonna Be tight on the frame rail….
I’m thinking that you could wrap your down pipe to carry heat to the doc.
You should have space for DOC…did you buy QD vband connector?
I couldn’t locate a 4-1/2” to 2-1/2 vband adapter…so for now I omitted the doc on mine
 

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MountainD

Technical Excellence Contributor
I’m thinking that you could wrap your down pipe to carry heat to the doc.
You should have space for DOC…did you buy QD vband connector?
I couldn’t locate a 4-1/2” to 2-1/2 vband adapter…so for now I omitted the doc on mine
yep, I have their adapter, very well made.
 

TheOneTen

New member
Where you have your muffler, I was going to try and put my DOC, if it would work heat wise for it to do it’s catalytic thing (Emissions in my area test/inspect for it). Do you think it could cram in there? I’m not sure any further downstream would be acceptable to them… gonna Be tight on the frame rail….
That was not the muffler - that was the 300tdi particulate filter. I ended up chopping it out and just putting a straight section in.
 
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