Intercooler improvement tips requested
 

Hello everyone,

after improving boost and fuel supply it's time to decrease head temperature.
As we know every degree we can cool down intake temperature equals in cooled down exhaust temperatures.

This is important in an heat sensitive engine like the Jeep Cherokee Diesel 2.5.
The intercooler is located below the radiator, behind the bumper.

http://up.picr.de/3620888.jpg


As you can see the intercooler is the black unit with both intakes on the left side. It is a double folded unit to increase surface area. Heat is transferred away with the engine radiator visco-fan.

http://s1.up.picr.de/3620890.jpg

How can I increase cooling performance?
The bumper blocks most of the air supply. On the other side it protects the low located intercooler.

Safety inspection demands to have that bumper.
What do you think about a custom intercooler in front of the radiator and A/C?
There is only a inch space avilable.:humm:

All thoughts are appreciated.
:hellox:

Have you considered liquid-to-air intercooling?

If you were into that, you could have a custom cooler built to utilize ALL the space you have available where the stock IC is now and a good radiator to circulate the water should fit fine in the inch of space you have in front of the stock radiator. It's a thought... Check out frozenboost.com and look at some of their liquid-to-air setups for ideas.

Just a thought...:w2:

Water to Air is what I'd do too in a confined space.

The radiator is small enough you could stick in anywhere and the cooler can be remote mounted up above the inner fender, where ever it fits.

I have an entire setup I'll sell ya cheap, only put 2k miles on it.

It won't fit into the engine bay.

I will improve airflow with slots in the bumper and increase flow with a fan of a bike-
Just to give you an idea how it looks like:

http://up.picr.de/3675083.jpg

The slots in the bumper will look like this Mercedes AMG G55. How do you like them?

http://up.picr.de/3675153.jpg

Air-to-water won't fit??? I'm going to have to beg to differ on that statement. You could have a air-to-water intercooler made that is roughly the same size, bigger if you can manage, and mount it exactly where your air-to-air intercooler is, then mount the circulation pump in an open, but safe spot, and fit the water cooling radiator in the space you have between the engine radiator and the grill. Seems to me like it would work pretty well, but that's just my two cents.

Cutting slots will likely help a little, and it'll be quick and easy, so I say go for it and see how it manages. Just remember that the more you take away from protecting it, the more likely you can damage it or cake it full of mud and bug guts, but you already know that. Hope it works out for you! :tu:

Thank you for sharing your thoughts.:tu:

A major problem of this engine is being extreme heat sensitive in the heads.

Under no circumstances I can obstruct the radiator.

I beg for every degree I can decrease coolant temps. ( I use a custom radiator and a coolant additive)
I dismounted also the aux headlights to increase airflow.
the engine bay is really jammed even if it doesn't look like that. The radiator cover contains the visco fan and the aux fan!
There an additional engine oil cooler mounted behind the bumper with a x-tra fan to assist cooling.

An additional coolant pumping circuit is installed to assist cooling during high loads.Even if you shut off the engine, the aux cooling unit runs up to half an hour to get coolant temperatures lower than 90°C or 194°F.
The original thought is to decrease inlet air temps to decrease combustion and EGT temperatures.

I take it there is no room for a small electric fan either? Remote mounting? it wouldnt be efficient but it would work.

:tu:
very good idea - I will check it!:humm:

Water injection?

Custom bumper with holes for air flow. Plus, you can make it a really badass bumper with towhooks and stuff.