A Vauxhall Zafira 2.0TDI

[Piwoslaw]

Here's a suggestion of how you should block your lower grille:

The green areas can be covered permanently, since they don't play a role in cooling. If you have fog lights in those corners, then just block what is closer to the center. The red area is in front of the A/C radiator, this block should be either removable or openable. You can also make an openable IC block, which would close when the engine is warming up. The blue lines show how the intercooler should be walled off, so that cool air is channeled only to the IC, without contaminating the rest of the radiator and/or engine bay.
Here is a picture of how I walled off my IC from the radiator.

Mike, why is there a silver tube going across your radiator (above and next to the fan)? Does that take intake air from the lower grille to the airbox? Maybe shortening it would be better, like to the top corner of the upper grille. I believe that the stock intake is at the top, correct?

[mikee55]

Hi Piwoslaw, looks good. The pipe is the intake. I moved it there for cool air. The original was at the top. If I've blocked the top grill, should I reopen enough for intake?

Thanks

Mike

[mikee55]

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Re your picture, how do you cut the shape behind the bumper?

Mike

[mikee55]

The latest


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Just need some sort of sponge/foam to make seal between pipe and bonnet/hood pipe.
Mike

[Piwoslaw]

Originally Posted by mikee55

Re your picture, how do you cut the shape behind the bumper?

It goes into the nooks and crannies behind the front bumper. I can't find any pictures of it at the moment, and probably won't be removing it, or have a chance to remove the covering panels, before it gets warm outside.

Now for something totally different: Have you considered removing the roof rails?

[mikee55]

Not likely.....
Hey Piwoslaw, how are ya? I need the roof rails on. I have a roof box to carry tent or beach stuff. Because I need all 7 seats, I have no room to carry anything. Shame, mpg will suffer with that on. The weather is starting to pick up in England these past couple of days. This means I can plug in my brief case. I have a folding solar panel, rated at 4 watts max. I just attached an on off switch, so I can charge the battery when the car is parked. Don't know how much it helps, but a well charged battery means less charging from the Alt, right? Hopefully will try to find the shape to isolate my IC. Will post some pics, when I get that done.

Mike

[mikee55]

I did some rough numbers. I bought a fiver's worth of diesel. £5.00. It got gave 3.85 liters. and I guesstimated that I drove 37.5 miles, before I went back for more fuel. My driving included mostly just myself, then, a phone call from the wife, because her bicycle had probs, I had to pick her up and I carried 2 kids and a bike on the roof. So, probably too many variables!

Have isolated my IC but not covered the lower grill yet. With the price of fuel about to go up, thanks to Gadaffi, I fear my car will be grounded!
Here in England I'm getting Diesel for £1.29.9p per liter!!
Mike