PDI Front Mount Intercooler Kit suitable for Toyota Landcruiser 80 Series

PDI Front Mount Intercooler Kit suitable for Toyota Landcruiser 80 Series

🚗This kit has options suitable for:

• Toyota Landcruiser 80 Series HZJ80 1HZ Engine 1990-1999
• Toyota Landcruiser 80 Series HDJ80 1HD-T / 1HD-FT Engine 1990-1999
• Toyota Landcruiser 80 Series with 1HD-FTE Engine Swap 1990-1999
• Turbocharger: Intercooler piping supplied in this kit suits a standard HDJ80 Turbocharger as well as all commonly fitted CT26 Turbocharger options from UFI, GTurbo, Arashi etc.

The PDI Intercooler kit for the 80 Series Toyota Landcruiser is designed specifically for the 1HZ, 1HD, 1FZ, 1HD-FT and 1HD-FTE engine in both automatic and manual variants. Where you’re towing, touring or chasing maximum horsepower and torque, this is the setup trusted by performance diesel owners Australia wide.

🔥 Why Front Mount?🧊

• The PDI Intercooler kit for the 80 Series features a large bar & plate style intercooler which runs a 585mm x 300 x 75mm core.
• Suitable for up to 400HP or 300KW.
• 2.5″ Stainless steel pipework which runs through the radiator support and fits with factory dual battery boxes.
• Custom made forward facing cast alloy intake elbow
• Heavy duty ‘Breeze Aero’ clamps and high quality silicone joiners, reinforced to handle high boost pressure.
• Optional high-BTU transmission cooler for automatic vehicles.

📦 What’s in the Kit:

• PDI Intercooler Core (Small or Large Core)
• Brackets for mounting the intercooler with additional bolts
• Polished stainless 2.5″ pipework
• Heavy duty silicon elbows and joiners
• Quality Breeze Aero clamps – better than all other screw type clamps and most T-bolt style.
• Instruction guide.
• Automatic Trans cooler: All Automatic options include a PDI Heavy Duty Transmission cooler as standard.
• Intake Adaptor: 1HZ/1HD-T, 1HD-FT and 1HD-FTE Crossover Delete options include a Cast Intake adaptor to remove the factory crossover pipe.

🧰 What You’ll Need,

• Normal spanners and sockets
• 3″ Hole saw and paint for protection.
• Metal snips for trimming lower panel.

This is a very popular kit, due to its effective and efficient design and you will find lots of positive feedback on many forums from owners.

🗣️ What Customers Say,

• Kim  – “Best mod I’ve done to my 80. Temps are way down, EGT dropped 100°C, and it holds boost hard.”
• Steve – “Switched from a top mount. Never going back.”

🛠️ Installation Details,

• The use of 2.5″ piping (to prevent a flow restriction) makes this harder to install while staying out of the wheel arches.
• The pipe routing is under the batteries on each side.
• Start by removing battery boxes, grill, headlight surrounds and metal panel below the grill.  The bull bar can remain fitted.
• Remove the centre bonnet support and install the replacement support bracket and bonnet latch.  This will also support the bottom of the intercooler.  Install the intercooler core.
• A 3″ hole needs to be drilled on each side from the front into the engine bay.  Once painted and pinch weld fitted, the pipe can then be fitted to the drivers side.  Silicon can be cut to length and then installed with clamps.
• Passenger side needs the brake line support bracket to be moved and then the piping will fit past it to sit just inside the top radiator hose outlet.  Install the custom inlet manifold adapter and then all pipework.
• If auto. the new transmission cooler comes fitted to the intercooler and should be plumbed up to the transmission.
• Reinstall new front panels, checking for clearance and eliminate any rubbing.  The lower metal panel can have a couple of long slots cut into it for more flow from the front.

🔗 The technical specs, if you like reading,

• When your goal is the maximum efficiency and power in your turbo diesel 80 Series Toyota Landcruiser then you need to go for maximum intercooler exposure and flow.
• Many Toyota Landcruiser 80 Series turbo diesel owners are happy with their power and are unaware of the gains that can be made with the upgrades.
• Intercooling can reduce the inlet air temperatures and make the engine more spritely and cleaner out the exhaust.
• Due to the ease of install, lots of people choose to go with a top mounted intercooler, as they simply bolt onto the engine and they get to install a bonnet scoop.  Scoops are cool, but the cooling of the inlet air temperature is not as effective with a top mount intercooler.
• It should be no surprise manufacturers only mount the radiators at the front behind a grill.
• At either high or low speed Landcruiser 80 Series Front Mount Intercooler Kits have out performed all top mount and front kits.

🔧 Testing, and why you SHOULD NOT use a top mount intercooler for your rig,

• If considering the purchase of a top mount intercooler then you need to consider the results compared to our Landcruiser 80 series Front mount PDI front mount kits.

📈 We even proved it,

In back-to-back testing, the PDI front mount kit dropped inlet temps from 260°C to 70°C at 100km/h uphill with 40+ psi. Outperforming top mount setups by a wide margin. Here’s some results compared to the best aftermarket top mounts on the market (when tested on a VDJ79 Toyota Landcruiser V8):

• Factory Top Mounted Intercooler: 88°C

• Upgraded Top Mount Intercooler: 75°C

• PDI Front Mount Intercooler: 47°C under identical condition – even dropped EGTs by 50°C at 110 km/h – proven protection and power.

• That makes the PDI Coolers front mount 3 times more effective than the aftermarket upgrade.

🤔 Why we used the parts we have with this kit,

• Utilising the heavy duty silicone and quality Breeze Aero clamps to seal between the stainless steel pipe, engine and intercooler, this unit will work flawlessly for many years to come.
• The use of a bar and plate intercooler was a no brainer for extra durability in the rough environment available to the adventurous traveller.
• Located behind the grill, this is less likely to absorb heat from the engine and will cool down quicker than any top mounted installation.
• Stainless steel pipework for both practical and aesthetic purposes.  The pipe work is not routed through the wheel arches, but rather they make their way directly into the engine bay after going through the intercooler. This reduces the risk of damage from thrown up sticks and rocks.

🚗 Auto Trans? No problem.

• For automatic transmission we use a Canadian made oil cooler with a high BTU rating and place it in front of your intercooler on custom brackets, tucked inside the grill.
• If the transmission is making excessive heat then it is better to priorities cooling of the transmission to protect an expensive part of your drivetrain.
• The bottom half of the intercooler, where the end tanks are located is still exposed to flow.

💡Will large spotlights affect the results?

This is a common question, and important question.

• We have many owners who regard these as the best unit they have fitted with their ability to provide cool inlet air. That is after trying top mounts and smaller front mounts.

• When tuning on the dyno we don’t have a large cooling fan in front so this simulates zero speed, high load situations with the only air being pulled through by the main engine fan.

• For most the alternative is an electric thermo fan attached to a top mounted intercooler. They are working to overcome the heat rising from the engine and from the cores close proximity to the hot engine. The insulation in a electric motor is rated to a certain temperature and the best quality units will switch off when they get to 130degC to protect themselves. Instead of assuming them to be at their best when you need them the most, on a hot day under high load, you need to expect to have zero intercooler efficiency.

• Front mount exposure compared to the opening in a bonnet scoop is significantly different. The placement is important as airflow over the bonnet into a scoop can be disrupted by bull bars and lights. Also some engine bays are positively pressured due to air hitting the front diff and other components – this means, just like your radiator, the best place to get cool air is at the front of the car.

🧊 Can I have the transmission oil cooler below the intercooler instead of in front of it?

• We have placed the transmission oil cooler exposed to the cooler air charge in front of the intercooler for space issues and the importance the transmission is given the best chance for a long life.
• The life of an automatic transmission is directly related to how cool it can be kept.
• If the transmission is making more heat due to the high load, this will reduce the effectiveness of the intercooler and results in making less power (a small amount).
• This is not a bad thing since if you kill your transmission, then you are both stuck and up for a large repair bill.
• Another aspect, most people aren’t aware of is that when the torque converter is locked up, there is little to no flow through the transmission oil cooler.
• Therefore once you are locked up, which is generally when above 60-70kph the transmission cooler is not reducing the intercooler cooling efficiency at all.
• We’ve seen the kits placing the transmission cooler down low behind the bumper / bullbar and don’t feel that will provide sufficient transmission cooling for a high power tune on the automatic.
• A number of transmission shops will tell you not to swap the factory transmission cooler for anything else. That’s why we use a quality Canadian built unit rated at 30,000BTU and ensure it will be able to get cool air. We have had people report slightly cooler transmission temperatures after the intercooler installation.

❄️ Transcooler details,

• Plates Dimensions Heat Dissipation Rating
• 12 plate 585mm x 150mm x 19mm   34.000BTU
• PDI 80 Series Front Mount Intercooler Kit
• This Intercooler Kit works great with the PDI Airbox found Here