Intercooler Conversion for 1.8TD

The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
For more information, visit the Ford Mondeo forum on TalkFord.com, the definitive resource site covering all Fords from the present day to the 1970's.

---

Overview Guide
Ford Model:	Mondeo
Petrol/Diesel:	???
Estimated Cost:	???
Difficulty?	???
How long does this take?	???

Intercooler Conversion for 1.8TD

Below is a diagram with all parts labelled. You can get the samco hoses and jubilee clips from www.demon-tweeks.com and the mikalor hose clamps from www.powerengineering.co.uk/mikalor

Before Starting

On a Mk2 Mondeo, it will need a small piece of the bonnet bracing cut out above where the RS-turbo pipe sits. You will also need a bleed valve on the turbo, or the boost will be way too high. You will need to turn up the fuelling on the fuel pump so that the car doesn't run too lean. You will need a boost guage to set the turbo boost level correctly. The bonnet sound deadening will need to be removed completely, as will the engine undershielding and black plastic panel under the front bumper.

Method

The intercooler fixes to 2 black plastic brackets with holes in them that stick out of the bottom of the radiator. I don't think this could be done on a car with air conditioning.

Drawn Diagram of pipework

Please note - my car has an alloy dump valve box made for where the existing black U-pipe is on the end of the intercooler

Top of Engine - Alloy Dump Box]

Bottom Pipework - Red

Bottom Pipework - Blue

Finished Pipework - Top of Engine

It's a very worthwhile modification and makes the 1.8TD much quicker than standard. It's virtually the same setup as on a modern 2.0TDCi mondeo. Pipe lengths, etc, all work out about the same. Also, there is no turbo lag (some people thought that there would be because of the long pipes, but as we know the 2.0TDCi also has these long pipes and that has no lag whatsoever). The standard top-mount position of the intercooler on a 1.8TD is pretty poor, and gets very hot through heatsoak in the summer months. This "FMIC" eliminates this problem and makes the overall power curve much better.