3.0d Intercooler

[nice1guv]

Hey Guys,

There appears to be no info on the web anywhere that I can find in regards to an intercooler upgrade for the E53 3.0d.

I can't believe no one seems to offer any upgrade product that is a direct fit for this car and engine combination.
There's plenty of universal intercoolers around, but I'm not keen on modifying them to fit.

If anyone has done their intercooler or know a place that supplies a direct off-the-shelf product, I'd love to hear about it.

[X5Sport]

You may well be safer just getting a remap.  If you mishandle a performance upgrade the gearbox will destroy itself.  These cars don't need upgrades which will be why no one does off the shelf kits.  There's no demand.

Plenty on here have very successfully remapped.

[nice1guv]

Yep, got a chip a year ago and it delivered great results, but straight out performance gain is not really why I'm after an intercooler.

I had my front bumper off recently and noticed the intercooler has taken a hit at some stage (previous owner!) and been pushed up at the bottom.
It doesn't leak, but must be restricting air flow and reducing cooling, although I don't have excessive smoke or any other concerns.
Anyway, I want to replace it, and thought if there was something that gave me more cooling then I would look at it.

[Greydog]

Not as diesel owner but what about an intercooler from the E70 4.0d or a 535d both have higher output engines. I know there are many engine/turbo differences but the cooling system and mountings may be close rnouh to allow fitting without to much pain. There will be some pain/head scratching whether you go after market or adapt from other models.
Have you searched realoem.com to look at drawings that may give a clue.

[chelsea]

....not 100% on this but don't intercoolers cater for a certain volume of air in and out  i.e bigger turbo then bigger intercooler? what would you gain putting a larger volume intercooler onto a standard engine?

[Insight G40]

A larger intercooler will cool the air more effectively and to a lower temperature. The cooler the air, the denser it is, and so more fuel can be added to increase power output.
Makes a big difference in tuning of petrol engines, but only really worthwhile in conjunction with other engine mods and above all a remap.

Not normally one of the first mods you'd make when tuning though.

The intercooler on my Polo was one of the last mods, vital when running nearly 200bhp out of a 1.3L 8v.

[nice1guv]

Thanks for the responses guys. 

I have looked at realoem and many pics; the E70 intercooler is wider and more of a box shape, I don't think it will fit into the space for the E53 one.
It also mounts quite differently, with a mounting plate underneath it, which the E53 does not use.

I already have a chip, and it rarely smokes, but a bigger intercooler would allow me to up the power from the chip if I wanted (not that I really want to though).
I also like to just play around and mod things every now and then.
An intercooler would help things keep cooler, smoke free, and just make the engine even happier.

Although, the main reason for the intercooler upgrade is to replace my damaged unit.
New ones are pricey, so I thought an aftermarket one couldn't be much more and wouldn't hurt.
I'm not talking about a massive unit covering the whole front of the car either, just a replacement unit made by an after market suppier that flows a bit more air.
I've replaced ones in Land Rovers before and I'm just a bit surprised that there appears to be not even one company that has an upgraded product out there for the E53 3.0d.

[kave]

If you find one let us know.  I would be interested, as intend to go hybrid turbo at some point, so will be affected by higher intake temps and heat soak.