D.I.Y. External oil cooler turbo RZR - Polaris RZR Forum - RZR Forums.net

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post #1 of 9 Old April 15th, 2017, 07:05 PM Thread Starter
 
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First Name: Curtis
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D.I.Y. External oil cooler turbo RZR

I just finished testing an external oil cooler and am happy with the results so I figured I'd share just in case other would like to do something similar. My primary purpose in adding an external oil cooler was to reduce the cooling load on the radiator as all 3 cooling systems ultimately really tax the cooling capacity of Polaris's design and in my opinion falls short of being able to cool the machine under spirited riding conditions.

The parts I used that came from Summit racing are as follows:
1. Oil cooler with fan #DER-15959 $176 8AN Fittings qty (1)
2. Fittings 3/8 NPT TO -8AN $ 3ea qty(2). #Sum-220846b
3. Fittings -8AN TO 1/2" barb 90 degree $12 ea qty (2) #Sum-260887b

The parts I used from HCT are as follows:
1. Oil sandwich plate $80 qty (1)
2. K&N oil filter 204 $12 qty (1)- PLEASE NOTE YOU CANNOT USE THE OEM OIL FILTER WITH THIS KIT ONLY THE K&N 204, if you try to use the OEM filter you will have a huge oil mess to clean up and may potentialy damage your engine.

The clamps that I used on the oil lines are made by Oetiker and are step less 15/16" that you install with an ear clamp tool. I have used them for years on high pressure oil lines without an issue. What you use is up to you but I am not a fan of the worm style hose clamps, I've seen too many strip out and am not willing to risk losing an oil line on my machine.

I also used qty (2) of some 3/8" NPT male to 3/8" NPT female 45 deg. Brass fitting off the sandwich plate.(see pic)

Some modification of the mounting bracket supplied with the oil cooler was necessary to install it in my desired location, I wanted it in the engine bay as well as protected from rocks and other debris so it ended up going in front of the turbo on the inside of the pass through access point. The bracket modifications were done with the use of a vice and hack saw (see pics) bracket has to be spread about 1" wider to straddle the plastic valley and cut to fit around the ECM.
Overall the installation took about 3.5hrs including installing a relay to run the fan. The fan pulls 4.8amps.
After testing for around 3 hrs today in the west desert, flying up and down some steep mountain roads and pushing it pretty good, the oil temp never got above 221 degrees ( I've seen 260 before) and the engine temp never exceeded 201.

There are a few different options I've seen on the forums for a project like this, this one requires basic hand tools and can be done by most mechanically inclined folks and will help reduce operating temps substantially.

Total cost approx $300
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Last edited by DuneGixxer; April 22nd, 2017 at 04:17 AM.
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post #2 of 9 Old April 21st, 2017, 03:30 AM
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Re: D.I.Y. External oil cooler turbo RZR

Thanks for sharing.
What was the engine temperature before the oil cooler?

Don’t argue with an idiot he will bring you down to his level and beat you with his experience
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post #3 of 9 Old April 21st, 2017, 06:40 AM
 
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Re: D.I.Y. External oil cooler turbo RZR

How long have you had it mounted there? That turbo gets very hot and might effect the plastic fan. Great idea for the access hole.
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post #4 of 9 Old April 21st, 2017, 08:41 AM
 
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Re: D.I.Y. External oil cooler turbo RZR

tag very nice setup thanks for posting
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post #5 of 9 Old April 21st, 2017, 09:04 AM Thread Starter
 
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First Name: Curtis
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Re: D.I.Y. External oil cooler turbo RZR

UAE,
The hottest I have seen my RZR's engine temps is 225, I monitor it closely and will pull over and let it cool down when it reaches 220. That was one of my motivations to add additional cooling, I don't want to pull over, I want to ride! I was also monitoring engine oil temp which I have seen in the 255-260 range, that is a ton of heat being dumped into the cooling system not to mention the accelerated break down of the oil under those temps. I just added the oil cooler within the last 2 weeks and have only been out the 1 time for about 3-4 hrs with four adults in the car, I did not baby the car this time, the hottest the oil got to was 221 deg and the hottest I saw the engine temp was 201. I believe it is definitely a step in the right direction. I will also add that I added my version of the HTC split tanks at the same time and that helps as well.

Manny,
The fan is about 6" forward and slightly lower than the turbo, I put my hand between the fan and turbo several time to see how much radiant heat was hitting it and the fan was still cool to the touch the whole time. The fan kicks on at 180 deg and moves enough air to keep every thing cool, probably even helps cool the turbo a little with this location.

The access hole from inside the car worked out nicely, I needed 2 short adjustable wrenches to tighten the AN fittings and had easy access through that opening. I think that's where Polaris should have mounted one! lol

Last edited by DuneGixxer; April 21st, 2017 at 10:50 AM.
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post #6 of 9 Old April 21st, 2017, 09:14 AM Thread Starter
 
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First Name: Curtis
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Re: D.I.Y. External oil cooler turbo RZR

one other note, I have a version of the reflex fan kit for the IC heat exchanger installed ( the fan I installed is a little larger than the reflex fan) and I did not use it even once during that trip. It is on a manual switch and typically I just turn it on and go, there was no need for it. I will keep it installed for now and maybe when the temps hit 100 around here I might need it- we will see.
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post #7 of 9 Old April 21st, 2017, 10:12 AM
 
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Re: D.I.Y. External oil cooler turbo RZR

can you give me the details on your version of the HTC split tanks? I have been wanting to do this but the cost has been holding me back.
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post #8 of 9 Old April 21st, 2017, 11:14 AM Thread Starter
 
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First Name: Curtis
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Re: D.I.Y. External oil cooler turbo RZR

I looked everywhere for a small expansion tank(s) that would fit the location and function, I had no luck. Ended up taking measurements, purchased tank filler necks and caps 1.3bar, weld on nipples and fittings and fabbed them up. I have a brake and tig welder and made them from .080" aluminium sheet. I built another set for a friend on these forums, he came over and we installed the set on my machine and went through the Polaris coolant bleeding process. It took me about 5 hrs to fab up each set of tanks, I see where HCT comes up with their pricing on these. I cut my friend a good deal on the tanks but I am not in the tank building business. I am happy with the results and encourage anyone that has the fabbing experience to build them. This was a poor design from Polaris to mix the IC coolant and the radiator coolant in the same expansion tank!
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post #9 of 9 Old April 21st, 2017, 12:21 PM
 
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Re: D.I.Y. External oil cooler turbo RZR

Thanks for the input in the tank I cannot weld good enough to do this but I do know someone that can!
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