testing of stock intercooler

ziembic

ziembic

Donating Member
Does anyone have any ideas on how to test the stock intercooler. My ty has close to three hundred thousand miles on the stock upper intercooler. I just ordered the lower heat exchanger from Dutchty, but I don't have the coin to go after a larger I/C. I have watched my temps on a scanner while under boost and it seems as if this system isn't working to its full extent. I have the bigger I/C pump hotwired, and the extra heat exchanger in front of the radiator. I have checked the hoses and haven't found any flow restrictions (including running the pump without the hoses attached to the I/C. I may be expecting more than what is capable from the system, but I was seeing temps close to a hundred degrees above ambient. Basic info on the truck is stock block and cam, upgraded turbo (unsure of actual part number bought kit from Rockford with 3" DP) 3 bar, matching chip, MSD,1.6 rockers. Any help would be greatly appreciated.

Jeff
93 TY 275,000 miles or so
2005 Subaru STI (sleeper no hood scoop or rear wing)
96 camaro (looks like it runs 10's but doesn't have a motor)
93 firebird(1stever fuel injected factory stock at mountain speedway paved oval short track)
95 camaro (whole car being stripped PM for parts availability)
96 camaro (whole car being stripped PM for parts availability)
 
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sytyguy

sytyguy

Moderated User
Re: testing of stock intercooler

Still have EGR?
If so, is the chip designed with EGR turned off?
What boost level?
Do temps rise abnormally even when you don't go into boost?
 
BigBadSmoosh

BigBadSmoosh

Picking fights on I-65 since 2013
Re: testing of stock intercooler

pressure test it, and see if there are any signs of leaks on the inside of it.

i'd run water through the ports on the back and see if it comes out without a problem.
 
ziembic

ziembic

Donating Member
Re: testing of stock intercooler

sytyguy said:
Still have EGR?
If so, is the chip designed with EGR turned off?
What boost level?
Do temps rise abnormally even when you don't go into boost?
Click to expand...

I do not have EGR hooked up anymore, boost is about 15.5 or so. Temps do not rise unless I am into the boost.

Thanks
JEFF
 
sytyguy

sytyguy

Moderated User
Re: testing of stock intercooler

Yeah, sounds like the IC system isn't up to par (not by design, but by function). Do as Eric suggested and pressure test it. Remove the upper unit and flush out the coolant compartment and clean the core. Put a water hose on one of the IC lines (to the CCHE) and make sure that water is flowing out of the other one at the same rate. Verify that the pump is indeed working.
 
K

kwick6

Donating Member
Re: testing of stock intercooler

with the pump running and cap off do you see any sign of movement of the water?
 
The Devils Own Chariot

The Devils Own Chariot

Active member
Re: testing of stock intercooler

My personal experience I think the stock intercooler sucks. Intake temps were always on the warm side. I had a Johnson intercooler pump hotwired with a lower intercooler scoop. I flushed the system and added coolant. It was a pain to get the air pockets out. The upper intercooler sits right over the hottest part of the engine. There is no cooling of the stock intercooler spooling on the line, unless you have a fan on the lower intercooler. With a front mount you have a radiator fans pulling some air through the intercooler. The intercooler pump is just another item for mechanical failure and drawing of current to the electrical system. After a run the intercooler fluid was boiling inside. I messed around with the stock intercooler enough and thats why I went with a front mount. I think there may be some weight savings switching to a front mount also. You dont have that heavy lower interooler and all that extra weight in fluid. Not to mention a FMIC with 3" pipe will flow better than the bottle neck stock one. I race in some hot lap events and the recovery rate of the stock intercooler sucks also. It’s really prone to heat soak.
Most people will stick up for the stock intercooler. I can’t say I was happy with it. I think running 24 psi on the stock turbo also had something to do with it. Here is a lot of heat being generated there. I can say that Alky Injection was way more effective at cooling than the stock intercooler.
 
BigBadSmoosh

BigBadSmoosh

Picking fights on I-65 since 2013
Re: testing of stock intercooler

there have been guys with stock upper/lower ICs running in the low 10s for years. If setup right it does work.
 
The Devils Own Chariot

The Devils Own Chariot

Active member
Re: testing of stock intercooler

smaug said:
there have been guys with stock upper/lower ICs running in the low 10s for years. If setup right it does work.
Click to expand...

I know this. But it just was not working for me. They could run the same numbers with a front mount. They would be gaining a more fail safe machince without a intercooler pump. what if the pump dies on a run? Then what? No intercooling and then boom? I love the look of the front mount under the grill also.
 
sytyguy

sytyguy

Moderated User
Re: testing of stock intercooler

Rookie said:
I know this. But it just was not working for me. They could run the same numbers with a front mount. They would be gaining a more fail safe machince without a intercooler pump. what if the pump dies on a run? Then what? No intercooling and then boom? I love the look of the front mount under the grill also.
Click to expand...
Potential for pump failure isn't the reason that most people swap to A2A. If it were, we'd all be in trouble, because a dying fuel pump can be catastrophic as well. Usually, the swap to A2A revolves around 1 of 3 or 4 reasons......lack of heat soak when subjected to repeated WOT blasts.....weight savings.......increased under-hood space......and look/fitment of a FMIC. However, A2A isn't for everyone (among other things....A2W can be better in the right conditions). Don't get me wrong, I like A2A and agree that it has it's benefits and is right for a lot of people, but I'm not about to discount A2W simply because an alternative exists or because a % of the population has chosen to yank it because it failed to impress.

Yanking the A2W for A2A when all he may have is a restriction is akin to killing a fly with a sledgehammer......esp. financially.

:2cents:
 
The Devils Own Chariot

The Devils Own Chariot

Active member
Re: testing of stock intercooler

sytyguy said:
Potential for pump failure isn't the reason that most people swap to A2A. If it were, we'd all be in trouble, because a dying fuel pump can be catastrophic as well. Usually, the swap to A2A revolves around 1 of 3 or 4 reasons......lack of heat soak when subjected to repeated WOT blasts.....weight savings.......increased under-hood space......and look/fitment of a FMIC. However, A2A isn't for everyone (among other things....A2W can be better in the right conditions). Don't get me wrong, I like A2A and agree that it has it's benefits and is right for a lot of people, but I'm not about to discount A2W simply because an alternative exists or because a % of the population has chosen to yank it because it failed to impress.

Yanking the A2W for A2A when all he may have is a restriction is akin to killing a fly with a sledgehammer......esp. financially.

:2cents:
Click to expand...


Yep I agree with you totally. I guess Im not really worried about the intercooler pump failing. Im more about getting a truck to be as fail safe as possible. The less moving parts and electronics a part of any system the more the reliability goes up. You are right its not a huge issue. I also think installing a front mount is realtively inexpensive if you make up your own kit. I prolly have $300 into my intercooler tops.
 
Brassmonkey

Brassmonkey

Cruzin' Mel Man
Re: testing of stock intercooler

I used this thread to ask the question, instead of starting a new one, since the original question wasn't really answered. There are a lot of opinions, but I don't see any clear data. Also, I got better times with the stock upper intercooler, than I do with an after market ATR style intercooler.

Static, I was asking for both air and water flow. Maybe I can find a machine shop around here that has a flow bench. I can do the water test myself.
 
It's just a six

It's just a six

Super Member
Re: testing of stock intercooler

IIRC, Connely's (SP) intercooler, they stated you would get a .1 drop in the 1/4 mile.

I has to flow better than a stock unit, the stock unit narrows smaller than 2" where as the ATR, Connelys etc is a straight shot 2":2cents:
 
S

Static

Member
Re: testing of stock intercooler

The upgraded cooler is larger physically but the "core" is a different design. Its a possibility that the aftermarket cooler has less flow. Heres the one I bought a while back.
SprintPhoto_br4dvm.jpg


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midnightbluS10

midnightbluS10

Banned
Re: testing of stock intercooler

Yes. I think you can get them from JWaller and RPM.

edit: Looks like RPM only sells their custom sheetmetal one. There is someone selling the ones that say "Intercooler" on the top with the checkers around it. Don't remember who, though. Possibly Sportmachines or that could be what JWaller was selling.
 
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