Thread: Td5 intercooler options

Are you running more boost? if not the gain would be very minimal maybe a little less restriction and a little more map

Are you having excessive intake temps? is this due to the turbo being worked to hard and generating excessive intake heat?

Would you be better off fitting a spray bar to your current cooler and see if you get a difference. Do this to see if you get any gains if you don't a larger cooler wont do a thing

And what are you trying to achieve?
You may find more luck with a better radiator and a cooler thermostat as a rough rule of thump is you loose around 10hp per 10degC temp increase in a petrol engine ( i have not seen dyno results for diesel's but i would imagen they will be similar as it is energy lost from from map due to extra heat in the intake and compression ) this is also why most engine dyno cell's run there water temp at around 60c as it makes them look better

map is Mass Air Pressure which is atmosphere pressure, atmosphere temp, the supercharging effect cylinder filling gives from atmosphere pressure, and supercharging/turbocharging pressure minus heat from the charge air.

Manufactures like high engine temps for emissions reason's and why every engine from at least the 80's run at over 90c now and some at over a 100c

Originally Posted by lyonsy

Are you running more boost? if not the gain would be very minimal maybe a little less restriction and a little more map

Are you having excessive intake temps? is this due to the turbo being worked to hard and generating excessive intake heat?

Would you be better off fitting a spray bar to your current cooler and see if you get a difference. Do this to see if you get any gains if you don't a larger cooler wont do a thing

And what are you trying to achieve?
You may find more luck with a better radiator and a cooler thermostat as a rough rule of thump is you loose around 10hp per 10degC temp increase in a petrol engine ( i have not seen dyno results for diesel's but i would imagen they will be similar as it is energy lost from from map due to extra heat in the intake and compression ) this is also why most engine dyno cell's run there water temp at around 60c as it makes them look better

map is Mass Air Pressure which is atmosphere pressure, atmosphere temp, the supercharging effect cylinder filling gives from atmosphere pressure, and supercharging/turbocharging pressure minus heat from the charge air.

Manufactures like high engine temps for emissions reason's and why every engine from at least the 80's run at over 90c now and some at over a 100c

I'm running plenty of boost....

However, my question is simply- is there much of a benefit from an aftermarket intercooler? Are they better ,I.e what kind of IAT reduction can be expected, or are they similar in performance to the d2a unit, which I doubt, but don't know for sure...

Originally Posted by shack

I'm running plenty of boost....

However, my question is simply- is there much of a benefit from an aftermarket intercooler? Are they better ,I.e what kind of IAT reduction can be expected, or are they similar in performance to the d2a unit, which I doubt, but don't know for sure...

Well as i said the easiest way to see if you would get benefit would be to setup a spray bar on the current cooler and see if you get gains if you dont a larger cooler wont help you

So plenty of boost you at 17 20 25 30 whats plenty that changes what you need in terms of cooling? also if your getting above 20 you want to be looking at a larger turbo anyway

if your still down at a stock 17 or so a larger cooler the gains will be minimal over a D2a you might get a 5 deg drop might being the word

I have a Serck intercooler on my 2002 EU3 D2 auto. All the usual , and a BAS remap.
My result is that I can run cruise control all of the time without a trailer without exceeding 700C whereas with a EU3 intercooler I was continually running over 700c on long climbs.

An example is Moonie Moonie hill southbound on the M1 when before the intercooler I had to button off half way up when the EGTs went over 720C , now it will climb to the top with cruise at 110-115Kph with EGTs at 650-700.
That is on a cool day say 20C.
IMHO there is a difference of about 50C.
Regards Philip A

Got back from a drive to town, sitting bang on 100 kph ( real speed ) flat road approx 15 kph headwind
Have full size UK manual spec serck ( auto trans cooler relocated )
Ambient temp 26 degrees
A.p 100.2
Rh around 60%
I.a.t 27.8 degrees
Boost 7.5 psi ( measured from cold side )
E.g.t 330-340
If I remember correctly I.a.temps with d2a cooler were in the 40's under same conditions ( see what yours are as close to these conditions)


If you don't have a boost box and have an accurate boost gauge plumbed in to the hot side you can get an idea of pressure drop using nanocom etc
My chemical injection doesn't kick in till 22 psi which obviously keeps things even cooler as well as giving an extra shove in the back

Originally Posted by discorevy

Got back from a drive to town, sitting bang on 100 kph ( real speed ) flat road approx 15 kph headwind
Have full size UK manual spec serck ( auto trans cooler relocated )
Ambient temp 26 degrees
A.p 100.2
Rh around 60%
I.a.t 27.8 degrees
Boost 7.5 psi ( measured from cold side )
E.g.t 330-340
If I remember correctly I.a.temps with d2a cooler were in the 40's under same conditions ( see what yours are as close to these conditions)


If you don't have a boost box and have an accurate boost gauge plumbed in to the hot side you can get an idea of pressure drop using nanocom etc
My chemical injection doesn't kick in till 22 psi which obviously keeps things even cooler as well as giving an extra shove in the back

Yeah, I've noticed my IATs are significant at times,but I'm making significant power as well, that's why I'm looking at the intercooler,I guess my only query was if the aftermarket ones were more efficient, it appears they are....
I'll check my temps later....

@100 kmh 31° air temp, 11 psi boost, (on a dirt rd), my egts are about 430, intake air temp avg 57°, I'd like that a lot lower,I put the boot in at one point and hit 100° IAT, is that too hot?

Cheers James

for cruising along you wont get much better then 20 deg above ambient like you have.

yes 100 is getting up there in temp

how much psi was it when you had to boot in it?

from the sounds of it you have an aggressive boost and fuel heavy map, to me you would benefit from a larger cooler.
If you haven't also put a colder thermostat in it

if after that your still having excessive intake temps you need a larger turbo so its not working as hard to generate the boost so colder temps

try to keep the egt below 550 constant 600 peak