Intercoolers: How much difference do they make?

[PRout]

That big intercooler must make a significant difference or it wouldnt be there. But just curious how much does it really help?



Does anyone have any before & after the intercooler air temp numbers?



I thought of this after reading the posts about infra-red thermometers. Got me thinking you could sure clear up some space dumping all that hose & the cooler in front. You could do alot with that space. But Im sure its not worth the loss in performance... right???

 

[klenger]

If it wasn't there, everyone would be bombing their trucks to add one. I suspect it helps alot.

 

[gitchesum]

Just ask the 1st Gen guys who don't have one. They'll tell ya.

 

[illflem]

The intercooler is just a Dodge sales hype name, the real name is charge air cooler and is used in many diesel engines. I've seen large stationary twin turbo engines with a cooler in-between the turbos and another before the intake. Air coolers make an immense difference in efficiency. Cooler air is denser than hot air, it holds more oxygen for a more efficient combustion process. Air warms as it compresses, at 30 psi boost the intake air can be 250°-300°, the "intercooler" lowers the temp to 30-40° higher than the outside air temperature, as much as 200°. Some of the 1st gen guys add coolers for good reason...

 

[Joe G.]

I saw the LSR truck at May Madness in Carson City a few years ago. It looked pretty stock under the hood except for a large turbo and an extra intercooler. It was in front of the stock intercooler in place of the A/C radiator. It looked like a pain to install and some material had to be removed to cram it in there. It must be effective to go to that much trouble to add an extra.

 

[Lil' Dog]

I had an 89 non-intercooled machine and Bombed it as far as I could without meltdown. With boost numbers below what the stock numbers are in todays machines, I could muster 1250°F pre-turbo empty in 5th at 100 MPH, 24 psi boost. Not really a towing rig thats for sure... Now I have the intercooled model and can go a little higher in the power catergory.



It is essential in this days demand for power from the smallest displacement pickup diesel on the market.



J-eh

 

[RustyJC]

On one of our 2-cycle spark gas pure turbocharged engine models, a 20 degF drop in air manifold temperature allowed BHP ratings to increase 12. 5%. Much of this was due to increasing the detonation margin (not a problem with diesels), but improved mass flow (more pounds of air per intake event) was a major factor as well.



Rusty

 

[PRout]

Originally posted by illflem

at 30 psi boost the intake air can be 250°-300°, the "intercooler" lowers the temp to 30-40° higher than the outside air temperature

250-300 degrees after being compressed by the turbo. . Wow, that sounds pretty hot.

 

[JoeyD]

Is there a chart or a guide that tells you how big of an intercooler you would need for an engine? Or do you put the largest you can fit?

 

[RustyJC]

Originally posted by jdecampo

Is there a chart or a guide that tells you how big of an intercooler you would need for an engine?

Actually, air-to-air cooler sizing depends on the amount of heat to be rejected (BTU's/hour) - a function of peak mass flow and temperature of the air coming from the turbo (generally with at least 10% added as a safety factor) and the desired final temperature - as well as the temperature and mass flow of the cooling air medium. If you're starting from scratch on a custom application, the cooler supplier will typically give you a data sheet to fill out with your cooler requirements which he will then use to size and price his offering.



Rusty

 

[Lil' Dog]

It comes down to the efficiency of the cooler and a few other details. The amount of air flow (CFH) and the heat transfer rate for the cooler. The early (pre 94) CTD's had fairly small intercoolers in comparison to the present day versions. Hense Banks developed a larger unit with better flow charactoristics and heat transfer.



The manufacturer of the intercooler should have a good grip on the heat transfer rates and flows. Now as to where these charts are... . DONNO...



J-eh





(edit) Rusty already beat me to the punch, with a much better response I might add. .