Maserati Biturbo

1983 2.0 Ltr Carb

 

Adding Intercoolers

 

Overview

 

The car is a LHD Italian domestic market model, imported into the UK in 1995. It came to me mostly unmolested, except for some custom wiring modifications, bits taped up, screw terminal blocks, Scotch-lok connectors etc. To be honest, under the dashboard looks a bit like multicoloured spaghetti ! I bought the car as a track day/fun car, so I can live with the elements of uncertainty that come with this type of modification. I think what I am referring to is called “character”.

            With the primary objective being a fast car, rather than a comfortable car, the Missioni “Sofa’s” have been removed from the front, to be replaced by Mazda 323 “Recaro” type seats (Very supportive and Cheap !). The Air-conditioning is also surplus to requirements, so this is to come out as part of this modification. The space taken by the Aircon radiator is to be the site for a pair of Air-to-air intercoolers. The heavy aircon compressor and the drier is also coming out !

 

The Kit

 

I went to see my supplier who had a pair of Air-to-Air intercoolers and a box of assorted pipes from different Maserati Biturbo models and variants. I came away with lots of spare pipes, clips and half an idea of what I was doing.

 

The Frame

 

 

First job was to remove the water radiator to gain access to the Aircon radiator, then remove the Aircon radiator, compressor and drier. Using the Aircon radiator frame as a pattern, I fabricated a frame to carry the intercoolers Using 1” steel box and 1” Right angle. After a trial fit in the car I realised that the Intercoolers were going to have to lean back in this frame so that the bottom hose is infront of the frame, but the top hose exits at the back of the frame to clear the headlights. I also had to grind cut-outs in the frame for the top hose outlet to assist in clearance. I used bits of right angle steel with 6mm nuts welded on to give the intercooler mounts. A quick clean up and coat of paint and it all looked a lot nicer!

The Plumbing

 

I used the 90º Silicone bend onto the turbo and the chromed steel pipe and the rubber to the bottom of the intercoolers off a car with the intercoolers similarly placed. The rubber pipework from the top of the intercoolers are cut down from some Ghibli hoses (Which normally mounts the intercoolers in the wheel arch) and some odd  bits of the original aluminium pipework cut to suit the new installation. All a bit of a bodge for now, but that will change soon as when I fit the Fuel Injection manifolds !

The result

 

It all fits ! Quite tight, but the proof will be in the testing. I can’t run the car at the moment as I broke the return to the header tank off at the radiator. That fixed, and I’ll be on the road again. Tee Hee !

 

 

 

Test Drive

 

All fixed and fitted with water, off for a quick test drive round the lanes of Leicestershire !

WOW ! Boost ! (Until the hose I forgot to tighten up poped off !) OK easy to fix ! I expected to pop at least one hose so I had taken spares with me. Back out and boosting again, and the difference in performance is noticeable. The boost needle is coming up into the 1st Red sector on the gauge now.

 

The verdict

 

If you don’t have intercoolers – get them !

 

Tim Bennett 31-3-03