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Water-to-air intercooler installation - 81 931
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chuck21401  



Joined: 20 Feb 2005
Posts: 262
Location: Annapolis, MD

PostPosted: Fri Mar 27, 2020 9:08 am    Post subject: Reply with quote

I received the mounting bracket today; thanks Dan.

For future reference, this is what it looks like.





I'm not sure but I think I need the part #2 in this diagram.

Bonded rubber buffer 931 110 136 00

Will check with the dealer to see if they can get one, otherwise seems like I could create one fairly easily with a trip to the auto parts store.


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chuck21401  



Joined: 20 Feb 2005
Posts: 262
Location: Annapolis, MD

PostPosted: Sat Mar 28, 2020 2:22 am    Post subject: Reply with quote

Part 931 110 136 00 is NLA from Porsche.

Anyone know the dimensions for that part?

This company has all sorts of them:
https://www.mcmaster.com/rubber-isolators
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Last edited by chuck21401 on Sat Apr 04, 2020 12:50 am; edited 1 time in total
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chuck21401  



Joined: 20 Feb 2005
Posts: 262
Location: Annapolis, MD

PostPosted: Sat Mar 28, 2020 9:31 am    Post subject: Reply with quote

I also posted on one of the Facebook 924 groups; someone suggested the part that is used to mount the 944 ICV. Part number 999-703-264-00


EDIT: I received this part and it's way too small. Looking at the 924 GT parts diagram again (found a copy here: http://www.924gt.com/docs/924petcatalogue.pdf), the nut (22) - 900 076 025 02 is M8.
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chuck21401  



Joined: 20 Feb 2005
Posts: 262
Location: Annapolis, MD

PostPosted: Sun Apr 05, 2020 11:32 pm    Post subject: Reply with quote

The intercooler mount is tapped for M8 x 1.25 threads. This vibration damping mount is 3/4 and 1 wide. 9225K72 from McMaster-Carr. https://www.mcmaster.com/catalog/126/1546/

I bought extras in different sizes...they were $2-$3 each.


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chuck21401  



Joined: 20 Feb 2005
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Location: Annapolis, MD

PostPosted: Sun Apr 12, 2020 5:56 am    Post subject: Reply with quote

chuck21401 wrote:

I pulled up an archive of the parts installation list so will work on acquiring these parts.

(4) 2.25" T-bolt clamps
(2) 2.25" silicone 45 elbows (black)
3/4" Remote inline filler cap
Bosch intercooler pump
(4) brass 1/2" NPT Male to 3/4" barbed 90 elbows for intercooler or heat exchanger
(2) brass 1/2" NPT Male to 3/4" barbed straights for intercooler or heat exchanger
10 feet of 3/4" flexible fluid lines
(6) 3/4" worm gear clamps
10-row radiator (11.5" x 5.75" x 2")
2.25" cast aluminum tight radius 90 elbow

I also plan to include a 944 expansion tank in the system.


Uncle Sam sent me my tax refund so I ordered everything today. Doing my part to keep the economy going.

I bought a used 944 expansion tank on Ebay.

Most parts were found on http://www.frozenboost.com/.

I bought the Bosch intercooler pump (with the Ford mount) from Summit racing.

The 2.25" cast aluminum tight radius 90 elbow was found on Amazon from CX racing.
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jacobroufa  



Joined: 18 Nov 2016
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Location: Rockford, IL

PostPosted: Sun Apr 12, 2020 9:05 am    Post subject: Reply with quote

All this makes me really wish I had asked Dan to add me to the list when y'all did the group buy this winter.. Gotta keep telling myself "just finish maintenance and get it running again and THEN you can think about upgrades".
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chuck21401  



Joined: 20 Feb 2005
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Location: Annapolis, MD

PostPosted: Tue Apr 14, 2020 1:58 am    Post subject: Reply with quote

jacobroufa wrote:
All this makes me really wish I had asked Dan to add me to the list when y'all did the group buy this winter.. Gotta keep telling myself "just finish maintenance and get it running again and THEN you can think about upgrades".


Well look at this way...you can learn from my mistakes. Stay tuned.
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chuck21401  



Joined: 20 Feb 2005
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PostPosted: Fri Apr 17, 2020 11:56 am    Post subject: Reply with quote

chuck21401 wrote:

I bought a used 944 expansion tank on Ebay.




So I don't think the 944 expansion tank is going to work. Now that I look at the tank...and 944 cooling system diagrams...this isn't going to flow coolant like I thought it would. The 944 turbo tank has an extra port to cycle coolant through the turbo...maybe that would work or maybe I'll skip the reservoir for now.


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Carrera RSR  



Joined: 08 Jan 2010
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PostPosted: Sat Apr 18, 2020 5:11 am    Post subject: Reply with quote

Go for a 951 tank, has two take offs
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ideola  



Joined: 01 Oct 2004
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Location: Woodstock IL

PostPosted: Sun Apr 19, 2020 3:27 pm    Post subject: Reply with quote

Pasting my email to Chuck here for the benefit of others:

The filler neck in my photos of the 931 Club Sport is at the highest point of the system, so it's in a good spot. If you want to increase capacity by having reservoir, I would recommend keeping it separate from the engine coolant.

If you use a standard 944 tank as in my 931 Club Sport, you can then use the OEM 931 coolant reservoir for the TMCC circuit. With some very minor tweaking / bending of the OEM bracket, it will fit in the stock location even with the 944 tank. This will give you a discreet circuit so you don't heat soak either coolant loop. I'm using this setup on the 941, only I don't have a TMCC on that car, I use the 944 tank for engine coolant, and the 931 tank for water-meth reservoir. See this thread for details: http://www.924board.org/viewtopic.php?t=37203

If you ever plan to add water meth, then you may wish to consider another possible location such as the battery tray; this would require you to install a smaller battery like I did in the Club Sport, or do a rear battery relocation kit, which I was planning to do on mine but never got around to it.

You want the pump to draw coolant FROM the secondary heat exchanger so that you are putting COOL coolant into the pump. You don't want heat soaked coolant going into the pump as it could heat stress it. The flow should be:
TMCC outlet (hot coolant coming out)
filler neck
reservoir (optional)
heat exchanger
pump
TMCC inlet (cool coolant going in)

The TMCC provides a port to accommodate the OEM overboost detection switch, which is also a convenient place to pull manifold air pressure signal for a manual boost controller (using a tee). There should be another port right at the circular portion that connects to the throttle body, which is a 1/8-27 NPT port for a water meth injection nozzle (optional, of course).

For plumbing in of the 944 reservoir, including parts list for hoses, see this thread:
http://www.924board.org/viewtopic.php?t=36438
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chuck21401  



Joined: 20 Feb 2005
Posts: 262
Location: Annapolis, MD

PostPosted: Wed Apr 22, 2020 4:35 am    Post subject: Reply with quote

Thanks for posting this information.

ideola wrote:
If you want to increase capacity by having reservoir, I would recommend keeping it separate from the engine coolant.


Absolutely. Good point to clarify.

Quote:
you can then use the OEM 931 coolant reservoir for the TMCC circuit.


My only concern with that idea is the size of the inlet port. The hose coming from the intercooler is 3/4 where as the top port on the 931 reservoir is 5/16".



Quote:
If you ever plan to add water meth


That could be an option down the road; glad that the intercooler has that port available. I'm going to post more pictures of the various components as I get things installed. I'll need to label the various ports to keep things straight in my mind. I wouldn't want to blow coolant through the WG by mistake.

Quote:
You want the pump to draw coolant FROM the secondary heat exchanger so that you are putting COOL coolant into the pump. You don't want heat soaked coolant going into the pump as it could heat stress it. The flow should be:

TMCC outlet (hot coolant coming out)
filler neck
reservoir (optional)
heat exchanger
pump
TMCC inlet (cool coolant going in)


Very helpful, thanks.

Quote:
The TMCC provides a port to accommodate the OEM overboost detection switch, which is also a convenient place to pull manifold air pressure signal for a manual boost controller (using a tee). There should be another port right at the circular portion that connects to the throttle body, which is a 1/8-27 NPT port for a water meth injection nozzle (optional, of course).


Good to know.

Quote:
For plumbing in of the 944 reservoir


Adding the 944 reservoir looks fairly straightforward.

Still not sure which way I want to go.

I found two other reservoirs that might work:

Magnuson Superchargers (looks like the one used in some Toyotas)
https://www.magnusonsuperchargers.com/product-p/31-12-02-093.htm


Supercharger Reservoir
https://boostdistrict.com/products/supercharger-reservoir?variant=12995371302965&gclid=EAIaIQobChMI3YDs-JP66AIVChgMCh0kXAUREAQYASABEgIURvD_BwE



I might skip the reservoir for now but I think it would be a nice addition.

I'm still waiting on some big hose clamps to arrive but hope to start the actual install soon.
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!tom  



Joined: 28 Aug 2006
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PostPosted: Wed Apr 22, 2020 5:10 am    Post subject: Reply with quote

Isn't a reservoir required to accommodate thermal expansion?
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ideola  



Joined: 01 Oct 2004
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PostPosted: Wed Apr 22, 2020 5:17 am    Post subject: Reply with quote

There does not appear to be enough heat gain / differential for it to matter in the case of the TMCC. The coolant does get warming, and builds a little bit of pressure, but it's nowhere near what an engine produces. No one I've sold these to has installed a reservoir, at least as far as I know, and there are no reports of pressure related failures in the circuit.
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ideola  



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PostPosted: Wed Apr 22, 2020 5:26 am    Post subject: Reply with quote

!tom wrote:
Isn't a reservoir required to accommodate thermal expansion?

But, to that point, it's worth noting that the expansion tank for the engine coolant circuit is technically not directly "in line" with the flow...it is "side chained" (having trouble coming up with a better term).

So if one were to install a reservoir and wanted it in part for thermal expansion, it would be ideal to locate it at the highest point in the circuit (a good potential spot is the battery tray), and use the inlet for overflow. If you were to do this, you could eliminate the filler neck and use the expansion tank for fill. This might also require some sort of thermostatic device.

Hmmm.

Where are the thermodynamic engineers when you need them
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Mike9311  



Joined: 14 Dec 2004
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Location: Chicago-ish

PostPosted: Mon Apr 27, 2020 10:30 pm    Post subject: Reply with quote

Dan is right, there isn't a crazy temp differential and I always looked to the hoses for expansion if needed.

The first intercooler radiator run on the silver '82 had plastic endtanks (like newer radiators) and it survived just fine.

When this intercooler runs you can place your hand on the turbo/passenger side of the intercooler and its warm/hot to the touch and then slide it over t the throttle body side and its a lot colder.

I also know Dan's CS setup has held up just fine over many years and was "stress tested" for sure

In the end, installing one won't hurt. See if you can follow Dan's advice on placement. For fun, place in a cooler you can fill with ice
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