Thread: Defender 300TDI Water to Air Intercooler

Originally Posted by roverrescue

Sounds like a good journey youve been on!
I wonder what temperature the charge air at the inlet manifold measures at with stock configuration, simple larger air-to-air IC or water-to-air IC?

Steve

Had a look on the drive in to work today and I am seeing ~65C inlet temp at 110kph on the flat.

This is on a stock intake configuration

Guys,
Bear with me, while I work out what happens when I attempt attachments...

Intercooler.jpg
Plumbing Schematic

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Top View

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Front View
The piece of foam on top of the elbow was the brilliant solution to a 'Tappet Noise' problem.

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Side View

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Elbow made from a section of an Exhaust Doughnut. Mk1 was made from several Silicon elbows with 2" exhaust pipe joiners.
The doughnut was a lot neater & smaller.

Bud, I'm trying to see whether an intercooler with a different configuration would save the 180deg bend, but I dont think you could do any better. Looking at the others from Frozen Boost I think the one you have is still the best option...

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Coolant Pump.
This bilge pump flow rate is a little high - it cavitates if run at full speed. It's been fitted with a crude speed controller, until I can work out what's the best speed to fix it at.
It has the advantage of the motor/impeller separating from the pump body. It makes bleeding easier, and means I could carry a spare that doesn't require disconnecting plumbing.

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Header Tank.
Mounted on the other side of the engine bay. Connected to the I/C via 6mm tubing.
This coolant system is un-pressurised. I could've Tee'd into the engine expansion tank, but I didn't want to compromise that system with my dodgy plumbing.

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Radiator/Old Intercooler Adapter
Lump of steel, turned down to 2". 1/2" copper tube silver soldered as a hose tail. Bleed hole at the top.
I don't actually recommend using lumps of steel. It's what I had, at the time.

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The Inlet to the I/C is almost the same level as the Turbo Outlet.

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I read in a separate thread that someone was having issues with their EGT Thermocouple dying, presumably from having a small bend in it.
This is a secondhand industrial 6mm thermocouple. I think it was around 350mm long. It was bent by hand, well past 90degrees, as well as the small bend needed to poke it into the gas stream inside the manifold.

Steve,
You nailed it.
I checked the tappets, again. No smoking gun there. A couple were worth tampering with again.
I finally noticed the top elbow I'd manuf'd had a shiny spot on top. This is the highest part of the engine, now. It's a big improvement on the fifteen silicon elbows, joiners & hose clamps I'd started with, but it still sit a bit proud.
This has been tapping on the bonnet lagging. Fitting a cushion to the top of it has removed all the rattly tappet noise completely. I had huge tears of joy rolling down my red, embarrassed face.

Thanks, again, for pointing out the obvious, intentional, mistake.

Cheers, Bud.

Not sure if it will help but you can kicker the bonnet up a few mm on the front stops and adjust the latch? May give a little more clearance? Or just hit the shiny but with a calibrated clearancing blow with your BFH.

Thanks for the temp of 65* Peter5111, any chance you would have an inlet temp off the flat at 110kph Bud? Just for comparison?

Steve

Originally Posted by roverrescue

Not sure if it will help but you can kicker the bonnet up a few mm on the front stops and adjust the latch? May give a little more clearance? Or just hit the shiny but with a calibrated clearancing blow with your BFH.

Thanks for the temp of 65* Peter5111, any chance you would have an inlet temp off the flat at 110kph Bud? Just for comparison?

Steve

Steve,
I'll work on the Inlet Air Temp. I think I've got enough gear lying around to do it. Might take a coupla days.

Peter5111,
Do you measure EGT? (before Turbo).
I do wish I'd taken the time to measure Charge Air Temp at a decent load - EGT > 650DegC. It'd be really helpful if someone has that data.

Cheers, Bud.

Originally Posted by Budley

Steve,
Peter5111,
Do you measure EGT? (before Turbo).
I do wish I'd taken the time to measure Charge Air Temp at a decent load - EGT > 650DegC. It'd be really helpful if someone has that data.

Cheers, Bud.

Sorry, my temps are direct from the Nanocom Evo.

I will do a run up the freeway sometime in the next week or so and get a stable inlet tamp at sustained high loads.

Regards,
Pete