Upgraded intercooler on the 1.8, 2.0 and the 2.2 TDCi.....

Hello all,

Well - looking at the few tuning parts for the Mk4 Mondeo, it is sad to see that you can't find alot. But you can do a direct intercooler change, almost plug-and-play on the 1.8, 2.0 and the 2.2 TDCi versions. When looking at this link, you can see that the three TDCi models use the same intercooler: http://www.adrad.co.uk/intercoolers/c…RD&model=MONDEO
Well, the UK firm "Airtec" do make an upgraded intercooler, listed for the 2.0 and the 2.2 TDCi, but as they use the same intercooler as the 1.8 TDCi, then it will fit this model as well. Look at the Airtec intercooler here:
http://www.autospecialists.co.uk/Airtecs-Mondeo…oduct-1074.html
The pics shown in this add, is not the intercooler used in the TDCi models, but the 2.5 T model. For the pics of a 1.8/2.0/2.2 TDCi intercooler compaired to an upgraded Airtec intercooler, please look at my own pics attached
And by the way, Airtec do make a upgraded intercooler for the 2.5 T model.... Just look here:
http://www.autospecialists.co.uk/Airtecs-Mondeo…oduct-1068.html
So - happy hunting for an upgraded intercooler for the TDCi models, I do hope there is a dealer somewhere in Germany so you do not have to order it from the UK.......
(A Ford tuner from Belgium told me that an upgraded intercooler, a sport exhaust, KN air filter and a OBD-program would kick a 1.8 TDCi from 125ps/320-340Nm to 155-160ps/380-400Nm, so just imagine what numbers you would get on the 2.0/2.2 TDCi???).......

Happy "Mondeo" hunting.....

http://www.autospecialists.co.uk/Airtecs-Mondeo…oduct-1074.html
---> Is that the one you've installed? Despite that sweet looking Airtec print
So you say it's "almost" plug'n'play. What has to be done to make it fit?

If he brings more power then I would like to have.

I just found out that there are two different types of the intercooler available.
The one made for the 2.2 seems to be a bigger and slightly more expensive one..

[Blockierte Grafik: http://i41.tinypic.com/kx2rq.jpg]

Hi there,
Yes thats the one. The one I ordered from Airtec, was the one they post as for the 2.0/2.2 TDCi. When you look at the pics I attached, you can see one small intercooler (my standard 1.8 TDCi intercooler) next to the upgraded one I got from Airtec.
The pic with the "solo" intercooler, shows a 2.0 TDCi intercooler I borrowed in order to compare the piping on the one I had standard on my 1.8 TDCi.....

When I say - almost plug-and-play - I had to remove the big plastic potrection plate under the engine to get more space in order to unscrew the intercooler hoses, the bolts at the metal clamps were stuck/coroded! So I replaced them with new ones when I had the chance. The job took me appx. 2,5 hours in total from start to finish. The Airtec manual said max 2 hours for the job!

Now I am going for a Blurfin OBD upgrade, but driving with standard the program works well. No turbo lag, but more "pull" when I give he car sone power I have no numbers on the increase of ps/Nm, but allready I can feel it pulls more and use les diesel....... Maby 3-5ps more, but atleast 15-20Nm more without th updated OBD program........

and the other?

Wir können auch Deutsch schreiben

Zitat von Hman

I just found out that there are two different types of the intercooler available.
The one made for the 2.2 seems to be a bigger and slightly more expensive one..

[Blockierte Grafik: http://i41.tinypic.com/kx2rq.jpg]

To get it to cool more for the 2.2, you can order a "fat" model that would bring even more ps/Nm. This is why you can get two models - this was the reason they gave me over the phone.
The "normal" size as I went for (the 2.0 version) is slightly thinner.....

must be taken of the TÜV?

I think so, but do you not have the permission to change your intercooler on your own?

I've been reading some stuff about upgraded intercoolers combined with remapped vehicles... Looks like that is just it what I was looking for.
In the past time I had some issues, .. Exhaust Temperature too high, particulate filter could not regenerate etc.
I guess I'm gonna give that beast a go. Looks really huge compared to the standard one.

About the german TÜV:
If you want to have it all legal, the device or spare part you are installing has to have some kind of certificate. Moreover you have to change your papers.
Otherwise there's allways the risk of being caught with an "illegaly" mounted device, which eliminates your permission to drive on german streets!!

Idk... isn't it kinda the same in Denmark, though?

But I guess I just have to take the risk on this one...

Btw, batcave.. My Mondeo's got a Bluefin

Zitat von Hman

I've been reading some stuff about upgraded intercoolers combined with remapped vehicles... Looks like that is just it what I was looking for.
In the past time I had some issues, .. Exhaust Temperature too high, particulate filter could not regenerate etc.
I guess I'm gonna give that beast a go. Looks really huge compared to the standard one.

About the german TÜV:
If you want to have it all legal, the device or spare part you are installing has to have some kind of certificate. Moreover you have to change your papers.
Otherwise there's allways the risk of being caught with an "illegaly" mounted device, which eliminates your permission to drive on german streets!!

Idk... isn't it kinda the same in Denmark, though?

But I guess I just have to take the risk on this one...

Btw, batcave.. My Mondeo's got a Bluefin

Hi Hman,
Well yes, you have to use parts thats made for your model. Tuning in DK is more or less illegal, any chances to your standard car must be approved from the makker AND tested for emmission! This more or less makes tuning in DK a total No-Go.....
BUT, you can change parts IF it is used on later models with out any ID change on the car, so in Real life I can not go for the Mk4.5 front on my Mk4 model without playing tax for the new model..... Stupid...... So we do not tune our cars, we make "sleepers" so you have to dig down into the engine bayto find any of the modifications
I have NOT had any of the issues you list, all works as standard - with the extra power on top So my next step (I do have the exhaust, KN filter and ERG blanked off) is the Bluefin OBD program! On a standard 1.8 TDCi Mk4 Mondeo the Bluefin will give around 18-24ps and 38-46Nm, so I am looking forward to see what numbers I will get with the extras I have on my 1.8.......

By the way, do you have an Airtec dealer in Germany?

@ Hman

Könntest Du netterweise für die im Englisch minderbemittelten hier wie mich z.B. das ganze mal grob synchron ins Deutsche übersetzen? Denke mal für die LLK Geschichte interessieren sich hier noch mehr. Wäre echt nice , danke.

Zitat von Leomondeo

Könntest Du netterweise für die im Englisch minderbemittelten hier wie mich z.B. das ganze mal grob synchron ins Deutsche übersetzen?

schließ mich da auch an da die Übersetzprogramme das nicht 1:1 wieder geben und es noch verschlimmern

Habe vorhin beim Googlen entdeckt, dass es einen mehr oder minder ähnlichen Thread bereits vor einer ganzen Weile gab:
http://mondeo-mk4.de/index.php?page…hler#post100705

Im Grunde habe ich batcave nur erklärt, aus welchen Gründen (zu hohe Abgastemp durch Bluefinchip) der größere LLK genau das Richtige für mich wäre und wie das bei uns in Deutschland mit dem TÜV läuft. Wonach sich herausstellte, dass der "TÜV" in Dänemark noch um einiges strenger sei was Modifikationen am Auto belangt.

Ich werde mir wohl den großen Airtec für den 2.2er in Silber zulegen und berichten. Wann genau, kann ich Euch nicht sagen. Ist schon ne ziemlich große Investition!

@ batcave: We do have an Airtec dealer in Germany, .. But not the one we're talking about.^^ More like Rexroth or Festo for pneumatic systems!
But it's no problem to order it in the UK.

@ Hman

Danke erstmal . Mit dem Airtec Händler in Deutschland meinst Du da den hier Klick mich ?

Hatte ich gar nicht gefunden! Habe nur direkt nach Airtec gesucht.
Bei RH fehlt mir aber die Information, ob großer oder kleiner Ladeluftkühler (auf der UK Seite gibt es abgesehen von Silber/Schwarz noch 2 Größen zur Auswahl).

Preislich liegen beide nicht allzu weit auseinander.

Wie meinst Du das mit "ob großer oder kleiner LLK"? Auf dem Bild ist der originale zusehen, der ist klein, und der Austausch-LLK ist der große. Oder interpretiere ich hier was falsch?

Zitat von Hman

I just found out that there are two different types of the intercooler available.
The one made for the 2.2 seems to be a bigger and slightly more expensive one..

[Blockierte Grafik: http://i41.tinypic.com/kx2rq.jpg]

Es gibt laut Auswahl 2 verschiedene Größen. Eine für den 2.0er und eine für den 2.2er.

Bei RH weiß ich nicht, um welche der beiden es sich handelt.

Ach so, na da wird wohl nur nachfragen helfen .

Interessant wäre dann noch ab der Unterfahrschutz wieder dran passt weil der LLK auf dem Bild soweit runter geht

also @ Hman meinste wir bekommen den Eingetragen?

der LLK scheint auf der anderen Seite günstiger zu sein als bei RH

mir gefällt auch der weise schriftzug AIRTEC wie der so durch den Grill unten schillert