Intercooler add on. Kjet

[djshimon]

Hey all,
1983 245 kjet. B21FT~180,000 miles. I really like this car, turbo is fun but upping boost will be more fun.
I'm adding an intercooler(npr) but this car has never been intercooled . Got all the pipes and the intake cold side elbow but not sure if i need a newer intake or if i can make the b21ft intake work. So the metal elbow pipe(blue)that connects to the throttle body i can't get to fit down onto the driver side bolt, do i need to make the bolt hole bigger on the elbow or get a different throttle body?

Also there's a pipe sticking up from the cold pipe that I've seen blocked/capped off in pictures, is this what i do? What is it for?

Thanks all, this site has been incredibly entertaining and helpful.

 

[smoothdurban]

The cold side pipe you have in pic to is to couple the intercooler to a b230 intake manifold and I don't think it will work with the b21FT manifold which is on your car. That pipe sticking up from it should connect (via a rubber rose) to your idle control value.

 

[Murploid1]

The cold side pipe you have in pic to is to couple the intercooler to a b230 intake manifold and I don't think it will work with the b21FT manifold which is on your car. That pipe sticking up from it should connect (via a rubber rose) to your idle control value.

You dont have to connect that to your control valve - cap it off.

 

[Redwood Chair]

That little plate with the stud sticking up is different [the stud is shorter] on a TIC car.

You should be able to drill that stud out and use a nut and bolt there however.

http://www.turbobricks.com/mods.php?content=art0002

 

[neptune]

Got all the pipes and the intake cold side elbow but not sure if i need a newer intake or if i can make the b21ft intake work. So the metal elbow pipe(blue)that connects to the throttle body i can't get to fit down onto the driver side bolt, do i need to make the bolt hole bigger on the elbow or get a different throttle body?

The intercooled cars have a slightly different bracket that elbow mounts to. I believe the non-intercooled bracket works if you rotate it? Check the ancient Intercooling a B21FT article.
Yes, you can swap to a B23/230 LH intake, but it is a lot more work than just making that bracket work. Stu Spencer's geocities site has a great walk-through and check the articles section for some updates various others have done. I did it because I couldn't find that cast intake elbow you have, but but given what you have now it is easier to make the B21FT intake work.

Also there's a pipe sticking up from the cold pipe that I've seen blocked/capped off in pictures, is this what i do? What is it for? View attachment 17446

As was said before that is for the CIS/idle motor on the B23/230 cars, but you'll want to cap it if you stick with the B21FT intake as you already have all that connected.

The cold side pipe you have in pic to is to couple the intercooler to a b230 intake manifold and I don't think it will work with the b21FT manifold which is on your car.

Exactly. B21FT uses a shorter hose with a length of rubber accordion hose to a metal elbow on the throttle body. B23/230 intercooled have a longer metal pipe and a rubber elbow connecting to the throttle body. Different daimeters too. Mixing and matching not helpful here, you'll need one or the other.

 

[djshimon]

You guys are awesome! Thanks everyone. I will probably drill out the bolt and use the elbow i have. Don't really want to change to a new intake at this time.

 

[dl242gt]

You will also need to move the oil cooler closer to the battery. Use the next bolt hole closer to the battery and angle the oil cooler away from the intercooler. You will also need to use some spacers to raise the intercooler up as it's about 2 inches shorter in height than the radiator and the brackets. I used rubber spacer blocks for coil springs to do that other people have used a two inch piece of wood.

The better than Volvos intercooler allows about 11psi without any other fuel mods. It's a good idea to get a wideband o2 gauge so you can monitor the engine. You don't want to go lean. It's also a good idea to upgrade the intank pump to the 740 turbo version.

 

[djshimon]

Thanks Dave!

 

[JohnLane]

OP you are giving it a charge cooler. For the effort you are going to... give it an NPR intercooler for no pressure drop across the core and ambient intake air temps.

 

[djshimon]

Hey JohnLane,
I have an NPR intercooler and it is in-not perfectly in, but in. I'm having a little trouble with routing the pipes that came with it- they don't fit that easily with the kjet system- but I will prevail and have more boost!
Thanks everyone for the help. I had found most of this information on the site but it is great to ask a question specifically and have it answered specifically. Time to make a build post I guess.
-Aaron.

 

[dl242gt]

FYI if you don't find the corrugated pipe for the cold air side to the intake elbow. You can buy a length of turbo silicone hose from a truck parts supplier and cut it to length. It is flexible enough and is thick walled so it can handle the boost. The stuff I bought is blue on the outside and is multi layer with red on the inside. I can get numbers from it if you need.

 

[djshimon]

If it's not too much trouble Dave, that would be very helpful, but I'll do some looking around too. One thread mentioned the Gates 26530 hose works but i measured with a tape and it's not long enough for my car.

 

[dl242gt]

Here is pics of the hose. It's not a truly flexible hose but the slight angle needed to goto the elbow from the cold side pipe seemed like it would work ok. You can also cut it and use for shorter straight couplers. I had to buy a 3ft piece for $70. There is also the aftermarket hose from do88.

 

[djshimon]

Thanks again Dave. Y'all are truly helpful.

 

[benflynn]

OP you are giving it a charge cooler. For the effort you are going to... give it an NPR intercooler for no pressure drop across the core and ambient intake air temps.

That?s right, my stock ic ran 300+ intake temps, npr is what ever the temp is out side, even when over boosting the stock t3, and ever since.

 

[benflynn]

If I were to do this, I would love to have the kjet on the other side like some pics I’ve seen, I’m guessing of stock ic cars, but nothing will unlock the power of that b21 like efi, kjet is awesome, absolutely awesome when stock or close to it and working well.