Thread: Defender 300TDI Water to Air Intercooler

Originally Posted by peter5111

A close approximation ;
9.5PSI
25C

I will have a closer look on Tuesday

Some rough numbers
With a 60% efficient turbo at 25C the air out is about 101C.
Cooling it to 65C is 47% effective intercooling.

If your turbo was 65% efficient (more realistic) then outlet air would be 95C and your intercooler would be removing 40% of the possible heat.

These numbers (40-47%) aren't that exciting, you can probably improve some parts of the system and improve it somewhat). How hot is the cooling water getting?

No idea , my figures are on a stock standard intake setup.

Originally Posted by peter5111

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

Nanocom, hey.... We're not still talking about a TDI300, are we??
Bolted on another Temp Tx, on the weekend. Got the following results:

100-105kph
400DegC EGT - Max 'normal' cruising. This is where I find I get the best Speed/Economy.
0.7b (ish..) Charge Air
60DegC Charge Air
55DegC Coolant
26DegC Ambient
These figures remained pretty stable for over 12km's, on the freeway south of Gundagai.
There's a decent hill at Gundagai that had the Charge Air go to 1.0b and 70DegC with 700DegC EGT. It cruised up the hill without struggling.
On the return journey, I pushed a bit harder than I would normally for the freeway. with the following:
110-112kph
450-500DegC EGT
0.85b (ish...) Charge Air
70DegC Charge Air
60DegC Coolant
26DegC Ambient

At that load (500DegC maintained), it was obvious that the coolant was struggling to keep up. Off the freeway, the coolant was soon back to around 50DegC and Charge Air below 60DegC.
I still reckon that this is an improvement on the Air-Air Intercooler, even if the numbers are marginal compared to what Pete measured. I think Pete's in a TD5, so I'm not unhappy to be matching the intercooler performance of that.
I can almost hear Dougal crunching the numbers, to remind us how average the efficiency is. Makes me wonder just how ordinary the original cooler is.
I think I'll have a scratch around the bottom of the toybox and see if I can find something to measure the air before cooler. Anyone know what maximum to expect?

Cheers, Bud.

Originally Posted by Budley

Nanocom, hey.... We're not still talking about a TDI300, are we??

Oops, missed that one

Numbers (off the TD5) from last night
24C Ambient

80 kph
80C IAT, 3.6 PSI

90 kph
65C IAT, 6.6 PSI

100 kph
80C IAT, 9.5 PSI

110 kph
85C IAT, 11.3 PSI

The TD5 Manual has 290,000 on it and I don't know if the intercooler has ever been cleaned. I do know the compressor wheel is pretty banged up and shows a lot of erosion on the vane leading edges (Rocker cover vent oil? )

Originally Posted by peter5111

Numbers (off the TD5) from last night
24C Ambient

80 kph
80C IAT, 3.6 PSI

90 kph
65C IAT, 6.6 PSI

100 kph
80C IAT, 9.5 PSI

110 kph
85C IAT, 11.3 PSI

The TD5 Manual has 290,000 on it and I don't know if the intercooler has ever been cleaned. I do know the compressor wheel is pretty banged up and shows a lot of erosion on the vane leading edges (Rocker cover vent oil? )

Thanks Pete,
I think that helps(?)
I've stuck, yet another, Temp Tx into the Intercooler to measure the Charge Air temp before the cooler.
At first glance, boost pressures of 0.7-1.0b are producing temps over 110DegC.
It'll be a day, or two, before I can get back to the freeway to get some steady-steaming figures.

Originally Posted by Budley

It'll be a day, or two, before I can get back to the freeway to get some steady-steaming figures.

Budley, just wondering if you got any more figures ?

After reading this thread, I've got an idea I'd like to get your opinions on.

1. fit a barrel type water / air intercooler between the turbo and the original air / air intercooler

2. plumb the water into the heater hoses of the 300Tdi, thus utilising the radiator and the water pump and keeping it much simpler (& cheaper). This also gives the benefit of 2 intercoolers (air/air & air/water).

I've seen a water cooled turbo piped into the heater hoses and I would never go for a water cooled turbo after that. The Defenders heater was turbo charged! Got very hot very quickly, but on the downside, dune climbing pushed the radiator temp way too high. When your engine works at 80 - 100.C and you chuck in a turbo that runs at several hundred degrees, the cooling system can't cope. But given the air temp figures here quoted, it would seem that the cooling system could cope with the intercooler.

Any ideas?