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water to air intercooler - part 2

chrisk1500

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Part 1 was covered on the last site.

Part 2 will be covered on this site.

As a quick recap - during Part 1 I acquired a WTA core and used a Bosch electric water pump to push the water through 2 trans coolers and up to a holding tank and then through the core.

This setup worked, but I felt that the heat exchange was not as efficient as it needed to be. The trans coolers only had 3/8" lines on it so water flow was greatly reduced.

For part 2 I am keeping everything the same with the exception of the heat exchanger.

I am going to use a B&M SuperCooler. Here is what B&M has to say about the model that I will be using:

B&M SuperCoolers are 100% aluminum construction and use stamped plates sandwiched together to create one of the most efficient oil cooling devices available. Not only does this unique design provide for maximized cooling through more efficient heat dissipation but it also provides a much sturdier cooler which is practically impervious to flying rocks or other debris. Suitable for all fluid cooling needs including: automatic transmission fluid, engine oil, differential fluid, power steering and turbocharger oil in circle track, road racing, off-road, tractor pulling and monster truck applications.

28,000 GVW
20,500 BTU
11'' x 8'' x 1-1/2''


130-70266.jpg



Seeing as how it can handle 20 500 BTU, I think this is a step up from my previous setup. I will get pics of everything put together once I get this in the mail....
 
More pics...
 

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Got the cooler today.

I installed it behind the grille.

It is in front of the trans cooler but I think it should be ok. I will keep an eye on trans temps and move the heat exchanger if I have to.

I had to shave a bit of the grille and remove one bar to get it to sit in behind there. I am quite happy with how it turned out.

Now I just have to run the lines and hook the pump up!
 

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Chris if trans temps get out of hand, install a Deraile or similar under the bed with temp switch controlled fan, that is what I have on mine, temp switch turns on fan @ 180F return fluid temp, I monitor trans sump temp & it never gets over 200F, great for stop/go traffic or slow 4wd driving where air across grille mtd cooler is not very good, also have the PML deep trans pan for extra 3.75 qts trans fluid.
 
Chris - did you turn the upper intake manifold 180* to route your pipe from the turbocharger? Any clearance issues with the fuel filter, "connector center", etc?
 
Upper is spun 180*.

I unbolted the connection center and the filter manager. They 'hang' out under the intake.
 
Done.

Running in 80* F weather at WOT for over 1/4 mile unloaded the IATs would hit 246*F and rising without the IC hooked up.

With the IC hooked up running in the same weather on the same day, I could get the IATs to barely touch over 190*F and then settle out at around 180*F.

It is maybe not as efficient as some of your ATA coolers but I do like having everything tucked up under the hood.
 
Maybe a bigger core would result in lower IATs....I think the 2" outlet is hurting me right now....

Oh well - high 100s are better IATs than mid 200s....
 
BTW - this is running with just water.....water wetter and antifreeze should increase the cooling potential a few degrees as well....
 
How much capacity is your holding tank and where do you have it located. Could you post a link to Part 1 for us. I am heavily try to decide which route to go. Do you have a cost estimate?
 
Go to the old site and do a search for water to air intercooler....you will find what you're looking for...
 
Snapshot with intercooler running:
Snapshot created 6/23/2008 7:26:23 AM
__________________________________________________________________
ENGINE SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
Engine run time: 00:22:24
Boost pressure (MAP): 21.5 PSI
Desired EGR: 15.23 PSI
Desired idle: 806 RPM
EGR pressure: 13.78 PSI
EGR duty cycle: 0 %
Engine coolant temp: 191.9 F°
Engine speed: 2400 RPM
Glow plug relay feedback: 0 Volts
Glow plug voltage: 0.1 Volts
Ignition voltage: 13.2 Volts
Wastegate duty cycle: 71.1 %

__________________________________________________________________
INFORMATION SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
PCM Calibration ID: 4735
Current DTCs: 0
Accel. ped. pos. 1: 0.71 Volts
Accel. ped. pos. 2: 4.33 Volts
Accel. ped. pos. 3: 4.02 Volts
Barometric pressure (BARO): 12.86 PSI
Battery voltage: 13.1 Volts
Fuel temperature: 121.3 F°
Intake air temp: 141.7 F°
Throttle position: 0 %
Turbo boost (Calculated): 8.64 PSI
Voltage reference sensor: 1.3 Volts

__________________________________________________________________
INJECTION PUMP SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
Actual injection pump timing: 38.28 Deg °
Cam reference missed: 0 Counts
Crank reference missed: 0 Counts
Fuel calibration: 115 Counts
Fuel rate: 28.75 mm³
Fuel rate - Cruise: 29.06 mm³
Fuel rate - Idle: 0 mm³
Fuel rate - Maximum transient: 79.69 mm³
Fuel rate - Throttle requested: 0 mm³
Injection pulse width: 1.85 ms
Injection timing - Measured: 15.8 Deg °
Injection timing - Desired: 16 Deg °
TDC offset: -1.94 Deg °

__________________________________________________________________
TRANSMISSION SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
3-2 PWM solenoid duty cycle: 0 %
Cruise target speed: 76 MPH
Cruise speed error: 0 MPH
Current gear of transmission: 4 Gear
Current torque signal pressure: 65 PSI
Current transmission ratio: 1:0.05 Ratio
Error between desired and actual shift times for latest 1-2 upshift: 0.18 Sec
Error between desired and actual shift times for latest 2-3 upshift: 0.05 Sec
Force motor (PCS) - Duty cycle: 26.6 %
Force motor (PCS) - Feedback current: 0.45 Amps
Force motor (PCS) - Reference current: 0.43 Amps
Time of latest 1-2 upshift: 0.25 Sec
Time of latest 2-3 upshift: 0.22 Sec
TCC PWM solenoid duty cycle: 6.2 %
TCC slippage: 1 RPM
Transmission input speed: 3216 RPM
Transmission output speed: 3213 RPM
Transmission temperature: 149 F°
Turbine speed: 2412 RPM
Vehicle speed: 76 MPH
 
Snapshot with intercooler turned off:
ENGINE SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
Engine run time: 00:39:39
Boost pressure (MAP): 21.9 PSI
Desired EGR: 15.23 PSI
Desired idle: 806 RPM
EGR pressure: 13.56 PSI
EGR duty cycle: 0 %
Engine coolant temp: 190.1 F°
Engine speed: 2400 RPM
Glow plug relay feedback: 0 Volts
Glow plug voltage: 0.1 Volts
Ignition voltage: 13.1 Volts
Wastegate duty cycle: 71.5 %

__________________________________________________________________
INFORMATION SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
PCM Calibration ID: 4735
Current DTCs: 0
Accel. ped. pos. 1: 0.69 Volts
Accel. ped. pos. 2: 4.33 Volts
Accel. ped. pos. 3: 4.02 Volts
Barometric pressure (BARO): 12.76 PSI
Battery voltage: 13.1 Volts
Fuel temperature: 129 F°
Intake air temp: 173.6 F°
Throttle position: 0 %
Turbo boost (Calculated): 9.14 PSI
Voltage reference sensor: 1.3 Volts

__________________________________________________________________
INJECTION PUMP SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
Actual injection pump timing: 38.19 Deg °
Cam reference missed: 0 Counts
Crank reference missed: 0 Counts
Fuel calibration: 115 Counts
Fuel rate: 30.94 mm³
Fuel rate - Cruise: 30.94 mm³
Fuel rate - Idle: 0 mm³
Fuel rate - Maximum transient: 79.69 mm³
Fuel rate - Throttle requested: 0 mm³
Injection pulse width: 1.84 ms
Injection timing - Measured: 16.2 Deg °
Injection timing - Desired: 16 Deg °
TDC offset: -1.94 Deg °

__________________________________________________________________
TRANSMISSION SENSORS
¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯¯
3-2 PWM solenoid duty cycle: 0 %
Cruise target speed: 76 MPH
Cruise speed error: 0 MPH
Current gear of transmission: 4 Gear
Current torque signal pressure: 67 PSI
Current transmission ratio: 1:0.75 Ratio
Error between desired and actual shift times for latest 1-2 upshift: 0.2 Sec
Error between desired and actual shift times for latest 2-3 upshift: 0.05 Sec
Force motor (PCS) - Duty cycle: 26.2 %
Force motor (PCS) - Feedback current: 0.43 Amps
Force motor (PCS) - Reference current: 0.43 Amps
Time of latest 1-2 upshift: 0.22 Sec
Time of latest 2-3 upshift: 0.22 Sec
TCC PWM solenoid duty cycle: 6.2 %
TCC slippage: 1 RPM
Transmission input speed: 3216 RPM
Transmission output speed: 3216 RPM
Transmission temperature: 155.8 F°
Turbine speed: 2412 RPM
Vehicle speed: 76 MPH
 
How much capacity is your holding tank and where do you have it located. Could you post a link to Part 1 for us. I am heavily try to decide which route to go. Do you have a cost estimate?


PM someone if you're not familiar with the "old site" - we probably can't say it here on the regular forum.
 
I am pulling the plug on this project.

The WTA intercooler works, but it is not as efficient as an ATA unit.

I can only get the IATs within around 60*F of ambient at cruise on the highway. From what I have read about guys with ATA intercoolers, they can get IATs within 30*F of ambient. That is a big difference.

In order for my WTA setup to be that efficient I would need a much larger core and a second heat exchanger.

I am going ATA instead, and will most likely lift the truck 2" to give myself more clearance.

For the record - WTA is feasible, it just takes a bigger core than I have. It is a pain in the ass to constantly check water level though...
 
Ah. Now I see what your PM indicated Chris, no need to reply to my question.

I managed to get my ATA to keep the IAT around 150f. That is with a little smaller core than several of the other guys are using, and I left my airdam intact under the bumper. I have a larger intercooler to go in with the new engine. Going from a 24x9 to the 24x12.
 
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