Intercooler - How does it work?

tonygadget · Post by **tonygadget** » Mon Nov 19, 2007 6:43 pm

A question about the intercooler please..

I blanked off both ends of the EGR pipe this weekend & was amazed at how much the gunk resembled crude oil!

When following the pipes etc managed to work out how the intercooler is all connected to the air filter & turbo -- but, is it just air inside the intercooler? I understand now some of the comments in other threads ie how can it work efficiently when its behind the air con & main coolant rads?

If it is just air in the rad then should I be worried that the bottom of the rad appears to be gunged up & slightly dripping the same consistancy of oil/crud that was in the EGR?

Ralph · Post by **Ralph** » Mon Nov 19, 2007 6:55 pm

It's just air pressurised by the turbo inside cooling air outside,
the cooling air comes under the air con and water rads not through
them look under the front, it should not drip oily gunk unless the
turbo oil seals are leaking a bit, only other thing I can think of
is if the crankcase breather feeds into the air cleaner or on the
suck side of the turbo, but it's too cold to go look.

Post by **Simon Jones** » Tue Nov 20, 2007 1:25 am

Have a look at http://en.wikipedia.org/wiki/Intercooler

apole · Post by **apole** » Tue Nov 20, 2007 9:24 am

Hi,

Intercoolers basically cool incoming air into the engine, principle being the cooler it is the denser and thereby more air can fit in resulting in more power/better combustion.

All intercoolers have a habit of getting gunked up with an oily residue, whether petrol or diesel. I've had many cars with them ranging from VW TDI's to Mini Cooper S's and they all suffer this.

You can clean them, not sure if it makes much difference but it's possible, I had an article on how to do this on the VW cars I could dig out but 90% of that is how to remove and refit them which aint much use on a Bongo.

I'd say unless it's really badly contaminated it's probably not worth the bother.

Andy

dandywarhol · Post by **dandywarhol** » Tue Nov 20, 2007 2:47 pm

The engine breather pipe feeds directly from the camcover into the turbo inlet pipe Ralph - so the intercooler will get gunge etc. from there.

Ralph · Post by **Ralph** » Tue Nov 20, 2007 7:36 pm

The engine breather pipe feeds directly from the camcover into the turbo inlet pipe Ralph - so the intercooler will get gunge etc. from there.
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That explains were the gunge comes from.

tonygadget · Post by **tonygadget** » Tue Nov 20, 2007 10:05 pm

dandywarhol wrote:The engine breather pipe feeds directly from the camcover into the turbo inlet pipe

Thanks dandywarhol.
I've had problems with petrol cars before where the breather pipe being gunged up has affected the running & emmisions. Is that the same on diesels & do you think it worth the hassle of cleaning?

On the pic (if it shows up) its the bottom 3 horizontal vanes between the bottom brackets that are oozing

Tony

[/img]http://s227.photobucket.com/albums/dd23 ... resize.jpg[/img]

tonygadget · Post by **tonygadget** » Tue Nov 20, 2007 10:07 pm

Hmph. Would never think I work with computers all day!

how do you embed a pic in the body please?

Tony-not-so-good-with-computers-gadget

francophile1947 · Post by **francophile1947** » Tue Nov 20, 2007 10:17 pm

tonygadget wrote:how do you embed a pic in the body please?

Just follow this guidance thread http://www.igmaynard.co.uk/bongo/forum/ ... php?t=9285

alphabetter · Post by **alphabetter** » Tue Nov 20, 2007 11:38 pm

tonygadget wrote:

[/img]http://s227.photobucket.com/albums/dd23 ... resize.jpg[/img]

You're on the right lines, but you've got a couple of problems there. You've got a "[/img]" tag at the start where you should have just an "[img]". Also I believe you can't include images with dynamic addresses (basically those with a "?" somewhere in the path) which you also have. In photobucket you can just copy the "IMG Code - Forums & Bulletin Boards" link from the page and paste that in.

tonygadget · Post by **tonygadget** » Wed Nov 21, 2007 1:15 am

Thanks you two

Looks like I'll be busy with the parafin gun this weekend

dandywarhol · Post by **dandywarhol** » Wed Nov 21, 2007 1:21 am

Can't quire see it in the pic but if it's oozing from the cooler itself then it must be leaking - and if it's leaking gunge out it must also leak blown air out. loosing you performance!

Ralph · Post by **Ralph** » Wed Nov 21, 2007 9:23 am

Ours is as dry as a bone, wounder if it's had a knock the brackets
look a little bent, but it could just be the angle of view.

tonygadget · Post by **tonygadget** » Wed Nov 21, 2007 9:38 am

I think your both right! It has got what looks like a crush injury (well spotted Ralph) approx 1/4".
What I've decided to do is remove it. Thouroughly clean it. Then blow compressed air through to see how much it leaks.

It doesn't look rusty through the gunk so if its just a slight split where its knocked at the bottom I might be able to weld the seam.

It does beg the question however about "unforseen problems" ie on an 11yr old Bongo are all intercoolers gunged up like a dose of bronchitis? & it takes a leak to reveal how much of the turbo blown gunk is settling in it.

smartmonkey · Post by **smartmonkey** » Wed Nov 21, 2007 12:46 pm

The intercooler is made of aluminium so you may have a job welding it. I think it is most likely to be a poor connection.