Intercooler questions

[johnboy]

Ive been given a intercooler and piping from a 1Z tdi Golf which Im thinking of adapting to fit my AAZ Passat. (Running 1.2 bar of boost, No EGR, Fuel screw tweaked)

Basically I just want to know what the effects fitting an intercooler will have on the engine.

Will I need to adjust the pump and boost to see any performance/ efficiency benefits or will I see gains with no adjustments?

Im not too sure about the theory behind intercooled diesel engines, (this is my first diesel) so help me out here guys!  :!:

[OM617]

An intercooler will not add any power to an engine. It allows more fuel to be injected safely for longer by reducing temperatures of the compressed air which lowers the exhaust temperatures.

[jtanguay]

Ive been given a intercooler and piping from a 1Z tdi Golf which Im thinking of adapting to fit my AAZ Passat. (Running 1.2 bar of boost, No EGR, Fuel screw tweaked)

Basically I just want to know what the effects fitting an intercooler will have on the engine.

Will I need to adjust the pump and boost to see any performance/ efficiency benefits or will I see gains with no adjustments?

Im not too sure about the theory behind intercooled diesel engines, (this is my first diesel) so help me out here guys!  :!:

you should do some searching on the topic.  when you compress something, the molecules are closer together, and bounce off each other at a higher rate, giving off more of their energy than at atmospheric pressure.  the most efficient psi without an intercooler is something like 10 psi.  anything above that and you lose efficiency due to the temperature being so high that the charge density stays the same as a lower pressure.  adding an intercooler lowers the charge temperature, therefore increasing the charge density at higher boost levels, which in turn CAN increase engine performance when given extra fuel (with pump mods).  

intercooler = okay for 10 psi, and good for 15 psi and amazing for 20+ psi.  and on hot days, it is even that much better (as long as you don't get heat soak in traffic)

benefits:

- extra performance (with pump mods)
- extended engine life due to lower EGT's
- less heat stress on motor, but offset by extra power stress (with pump mods  :twisted: )

as long as your car doesn't smoke too badly you should be fine.  get a 3" exhaust system from Dave @ PP and rest assured your car engine won't die from EGT failure (unless you're insane and run some crazy fueling+boost :twisted:)

[nogama3]

johnboy, i am in the same boat as you and am trying to ad an intercooler of a Golf TDI onto my AAZ engine. Managed to get soe stainless stell pipe made for the pipe work so just need tme to fit it all and try it out. will be santa pod tomorrow at GTI Festival show in Northampton and may tae my motor on the strip.
I have had the boost adjusted to 1.2 Bar and removed the EGR valve and the fueling tweaked by Gavin at the Derv Doctor.

Currently running at 95 bhp (Stealth Racing print out). I have been told that i will get another 10bhp if i add the intercooler. fingers crossed then....

keep me posted on how you get on with yours.

[nogama3]

see this post:

http://vwdiesel.net/phpBB/viewtopic.php?t=5716&highlight=intercooler

might help...

[johnboy]

Ok guys thanks for the info.
The basics I think I understand. Cooler air into the engine = lower EGT = the ability to run more boost and fuel = more power.

What effects would an intercooler have on my engine WITHOUT any more boost or fuel?

Correct me if Im wrong, but from what jtanguay is saying, because Im running about 15psi I might as well fit the intercooler as it will make the combustion cycle more efficient, and will give me the opportunity to add more boost and fuel at a later date if I see fit.

[johnboy]

By the way nogama3, the golf looks well! You dont happen to have a spare VR6 lower splitter do you?

[OM617]

What effects would an intercooler have on my engine WITHOUT any more boost or fuel?

About 1-2hp from more efficient combustion and less heat stress in the engine's internals/turbo.

[nogama3]

By the way nogama3, the golf looks well! You dont happen to have a spare VR6 lower splitter do you?

seen one on ebay, item no: 180137642923

good luck

[burn_your_money]

 and less heat stress in the engine's internals/turbo.

What about cracks between the valves? Wouldn't the temperature difference between intake and exhaust increase with an IC?

[jtanguay]

 and less heat stress in the engine's internals/turbo.

What about cracks between the valves? Wouldn't the temperature difference between intake and exhaust increase with an IC?

then offset it with more fuel  :twisted: