Adding an intercooler (Xsara Picasso)

[Harlequin]

Greetings all!

Dont suppose anyone has a diagram of how to add the 2.0 hdi intercooler from a 110bhp to the 90bhp on a 2004 xsara picasso do they? the pipes and the what not please?

[wheeler]

Dont think the Xsara Picasso was ever fitted with a 2.0 HDi 110bhp engine?? not in the UK anyway that im aware of.

[wheeler]

The 1.6 110 bhp had an intercooler but as the engine is a totally different engine layout so custom pipework would need to be made.

[Harlequin]

What about from the Xsara into a similar age picasso?

[Paul-R]

Despite the similar names there's very little in common mechanically between the two models.

[wheeler]

Agreed, the Xsara is a totally different car.
I think trying to fit an intercooler to a vehicle & engine combination that was never designed to have one would be a lot of work & need a lot of fabrication.

[MattBLancs]

I've not done this, but I have considered it on another car:

I've a 306 HDi, that only ever came with the 2.0 8v 90 bhp non- intercooled variant.

The similar Xsara lived a bit longer and so, I think only in 3 door "Coupe" form, could be had with the 110 bhp intercooled HDi.

Things I'm aware you'd need to change/overcome:
Inlet manifold "elbow":
on 90 bhp it points towards the turbo (i.e. points down from manifold)
On the 110 bhp it loops up and forwards (i.e over the top of the cylinder head towards front of the car)

Turbo outlet:
On the 90 bhp it points upward (towards where the inlet manifold connection)
On the 110 it points downwards to a hose that runs under the sump.
I think the turbo is actually different between the two from memory. I've read of disassembling the turbo inlet housing, removing a small roll pin and "clocking" it around to point downwards.

I'm not sure if 306 (or Xsara Picasso) has the mounting positions for the typical 110 bhp intercooler.

Other points of note:
1.6 HDi 110 intercooler is different (front mounted but inlet and outlet both at the top)
Earlier 1.9 XUD often had a top mounted intercooler that's not suitable. The front mounted XUD intercooler (which has a different inlet manifold that points forward) I don't know much about.



Just to note the 306 is in long term "I hope to get around to it one day" as has borderline terminal corrosion issues (both inner wings and bulkhead both holed).

I have bought a 110 HDi inlet manifold complete with the other inlet elbow form as described above.

[MattBLancs]

Here's a spot of inlet manifold decarbonisation - this is the 110 bhp manifold.

[MattBLancs]

Here's an old thread in another forum covering fitting an intercooler to a 306 HDi

https://www.306oc.co.uk/forum/showthread.php?tid=29759