intercooler for a 3B

[eleblanc]

So i'm looking for a intercooler.

I've measured for hours and trying to fit a air to air is...possible but the piping is going to be a nightmare if possible. That is on my Bj42, with 2 battery tray.

Sooo. i'm looking for a water to air.

First, why i want one, because since i've installed my turbo i've played ALOT with fuel, and i, now, found the sweet spot. For exemple, if i run on the highway at 100kph on a steap climb, at max pressure (10psi) if within 2-3 minute EGT reach 1000deg F, about 3-4 minute later water temp will start climbing at a high rate, within 5 minute it will reach 210-220 and if pulling the trailer 225 and more. if i cut down on fuel, going a steap hill at 100kph max boost, the EGT will go over 900 but will stabilise at 925-930deg F and at that EGT temp, water temp won't raise like crazy. it will raise to 200 but stabilize there.

The difference in water temp increase is very suprising. EGT go over 950 and near 1000 and water temps goes balistic. If i can keep EGT under 930 water temp stabilise.

I tried turning the fuel many many time, i even turn the thing one more full turn, and the power difference is ALOT. But EGT and water temp juste goes nuts.

So i don't want more pressure, i want to keep water temp to a normal level even when i run max boost for 10-15 minute or more.

searching here i found this place.
Air to Water Intercooler

I emailed them to have them suggest me what i should install
i have 11" between turbo and throttle elbow. And at the same time see if i can hook up this directly to the motor water coolant.

I know you'll tell me cooling combustion air with a heat exchanger from the engine water is kinda basicly just like i'm setup right now. The water will eventually raise just like it does right now.

Maybe a second rad is in order, because installing water lines is ALOT easier then a 2" pipe, for a air to air intercooler.

We'll see what they tell me.

Also i've been searching to find the denco site that have water to air intercooler but no luck.

 

[tasnolan]

Here you go, very interested to hear of your results

Denco Diesel + Turbo - Intercoolers

 

[eleblanc]

Here you go, very interested to hear of your results

Denco Diesel + Turbo - Intercoolers

Thanks

I'm wondering if the fan on the rad is really necessary if you install it in front of the engine rad.

Denco is in Australia, so since i'd like this to be setup quickly i will be talking with the frozenboost guys on monday.

But concerning the Denco setup, i wonder how the inside of the tube is built.

 

[tasnolan]

I'm wondering if the fan on the rad is really necessary if you install it in front of the engine rad.

Probably depend greatly on the type of driving you are doing, would suggest not if you're only really using it on the highway. Why not air to air if you are placing it in front of the radiator anyway?

 

[Diesel42]

You've got my attention. Interested in seeing your results. If you were to install one of the frozenboost systems in between your turbo/throttle body, th ewater lines would sure be eay to route. Easy install, compact system,low cost($149.00 for the air/water cooler),plus a couple misc.fittings. If it works as they claim, that's a cheap worthwhile mod that i too will pursue. Keep up posted Eleblanc.

 

[Dougal]

If you're running engine coolant through a water/air intercooler then you need to be pushing upwards of 12psi boost, otherwise you're heating the intake charge (interheater, not intercooler).
A second water circuit (with radiator and pump) is the only sensible way.

But I suspect your heating problems aren't intake temp related, but rather power related.
Quite simply if you're producing 50% more power than stock, you're putting 50% more demand on your cooling system.

Time for a bigger radiator?

 

[eleblanc]

Probably depend greatly on the type of driving you are doing, would suggest not if you're only really using it on the highway. Why not air to air if you are placing it in front of the radiator anyway?

Because i can route a 1" water pipe easily. Not a 2" air pipe unless i do some major changes.

 

[eleblanc]

If you're running engine coolant through a water/air intercooler then you need to be pushing upwards of 12psi boost, otherwise you're heating the intake charge (interheater, not intercooler).
A second water circuit (with radiator and pump) is the only sensible way.

But I suspect your heating problems aren't intake temp related, but rather power related.
Quite simply if you're producing 50% more power than stock, you're putting 50% more demand on your cooling system.

Time for a bigger radiator?

Probably and i am looking at that also. But from the talk i have done with diesel specialist, They told me that it is mostlikely air temp from the turbo causing this. Anyhow if the froozenboost is not expensive it is worth a try. The engine water temperature raise is really related to the EGT.

 

[crushers]

i am installing a air to air top mount IC on a 40 series witht he induction under the hood... of course induction through the hood is easier but the cusotmer wants the truck to look factory from 20 ft when completed

 

[crushers]

i find your findings about water temp and EGTs interesting since i have found no coralation at all between the two systems...i have monitored the 2 systems on various Toyota diesels extensively over the last 4 years...
very interesting indeed

 

[seapotato]

My old 45 with turbo and ic would heat up a bit on long stretches with 1100 f egt's, but it took a minute or two, I had a huge rad in the truck so it never came close to overheating, but the temps did go up.

And usually when I saw the egt's get that high, I'd back off a bit. Not just because I knew the poor little 3b was working hard, but because of the fuel it was sucking down at those temps.

The intercooler made a surprizing difference, and mine was just a cheapo aluminum one from ebay.

Despite people saying they make no difference unless you have x amount of boost, it did in fact make a big difference.

Well worth the effort of putting it in. I had moved the batteries into the bed of the truck to have room for the piping, that stuff uses up your free space in a hurry.

Don't think I could've fit the thing in there without moving them.

 

[eleblanc]

So right now the only one that will fit is this one

Water to Air Intercoolers

Now, what size heat exchanger i need?

Water to Air Heat Exchanger

I won't order a fan, since i will mount this in front of the existing rad

 

[eleblanc]

My old 45 with turbo and ic would heat up a bit on long stretches with 1100 f egt's, but it took a minute or two, I had a huge rad in the truck so it never came close to overheating, but the temps did go up.

And usually when I saw the egt's get that high, I'd back off a bit. Not just because I knew the poor little 3b was working hard, but because of the fuel it was sucking down at those temps.

The intercooler made a surprizing difference, and mine was just a cheapo aluminum one from ebay.

Despite people saying they make no difference unless you have x amount of boost, it did in fact make a big difference.

Well worth the effort of putting it in. I had moved the batteries into the bed of the truck to have room for the piping, that stuff uses up your free space in a hurry.

Don't think I could've fit the thing in there without moving them.

right after your install, if you did not increase the fuel, what would be a average number in EGT drop you got?

My guess and what i hope, is if i can lower EGT about 100deg F all my engine water heating will be gone.

 

[seapotato]

The drop was at least 100f. more like 200 -250.

Really noticed it on long hills, where before I could wind it up to 1200 degrees without too much trouble, same section of road I'd be barely cracking 1000.

And this was at a max boost of around 10 psi. maybe a bit less.

 

[RufusTheDufus]

Well worth the effort of putting it in. I had moved the batteries into the bed of the truck to have room for the piping, that stuff uses up your free space in a hurry.

Don't think I could've fit the thing in there without moving them.

I'm going to be installing an intercooler in my 42 when I do the engine swap. I'm thinking about designing a set of replacement battery trays in SolidWorks to make the plumbing go a little easier. I wonder if there would be a market for them?

 

[eleblanc]

My only concern now is the pump, it runs 12V, i can easily run it on my converter, but i'll be just more draw from it.

 

[Dougal]

Probably and i am looking at that also. But from the talk i have done with diesel specialist, They told me that it is mostlikely air temp from the turbo causing this. Anyhow if the froozenboost is not expensive it is worth a try. The engine water temperature raise is really related to the EGT.

Remember that your EGT readings are a very good indicator of how much load you're putting on the engine.
I think the reason your engine is heating is because above X EGT's your engine is pumping out more heat than your radiator can shed.

Just for comparison, my Isuzu is currently being fed 20psi with no intercooler. Intake temps can be over 130C, EGT's up to 750C. The cooling temp is stable.

An intercooler is still a good thing to add, I'm just not convinced that it will solve your heating problem.

 

[eleblanc]

Remember that your EGT readings are a very good indicator of how much load you're putting on the engine.
I think the reason your engine is heating is because above X EGT's your engine is pumping out more heat than your radiator can shed.

Just for comparison, my Isuzu is currently being fed 20psi with no intercooler. Intake temps can be over 130C, EGT's up to 750C. The cooling temp is stable.

An intercooler is still a good thing to add, I'm just not convinced that it will solve your heating problem.

Dougal, Maybe you are correct and i'm wrong, i will find out very soon. One way or the other it won't make things worse. All info lead me to think my intake temps is probably high, too high with the fuel load i'd like to run.

Worse case scenario, i install a intercooler for about 500$ and it turn out to be a 300$ rad..at the end i have a new rad and a intercooler.

What make me think it is the intake temp is that if i turn the fuel 1/5 of a turn down, temps stays under 210 even at max boost for 10-15 minute. If my rad would be the problem i would probably still have heat issue. But when i turn the fuel up 1/5 of a turn, water temps goes balistic in the same load situation.

 

[Spallet]

Put a higher capacity radiator and intercooler at the same time...

 

[eleblanc]

I placed the order, so for 535$ delivered in Canada i get the water to air intercooler, 1x radiator, 1x bosch pump, 2x silicone reducer, 4x clamps, 4x 1/2" to 3/4" barb elbow, 1x remote radiator filler cap.

Missing; the 3/4" hose, support for rad and intercooler.