Hi guys
Dont know if anyone is intrested, but we began development at work on an upgraded intercooling system for the 3.2 DID yesterday. The test mule is an NP GLS with 180 000km's on board.
As we all know the standard location of the factory cooler is less than ideal as it has minimal airflow and is prone to damage and clogging with mud etc. The core whilst being quite long has a very small stacked height, this combinded with the small tube sizes means that the cooler would be very restrictive. It is a common misconception that restrictive coolers must cool better, but it is far from the truth. As the amount of flow area( number of tubes x inside diameter of tubes) of the OEM core is quite small it means that the air has to speed up through the core. This means that as the air speeds up through the core it has less time to transfer its thermal energy into the coolers tubes. A larger higher flowing cooler allows the air speed to slow through the cooler thus allowing the air more time to be in contact with the internal surfaces of the coolers tubes and thus more time to transfer its load of thermal energy.
Ok, so while we had a fair idea that the OEM cooler wouldnt be that great, we were quite suprised on thermal load testing just how bad it can be! The ambient temp today during testing was 18deg C. A good intercooling system will be able to keep inlet temps to no more than 20 degC above ambient. My old 700hp Turbo Commodore maintained no more than 10degC above ambient on full noise. The 3.2 Paj showed us quite quickly that temps out of the turbo would exceed 150deg C on full noise, about the norm for most turbo deisels these days. The dissapointing thing is that after the cooler, temps were 116degC on the first run and then 126degC on the second run and still climbing. Please remember these are just quick power runs on the dyno taking no more than 15 seconds. I would love to hook a trailer on and test it full load up a hill but feel that would be not very nice to the vehicle at all. For obvious reasons these kind of inlet temps are not in the vehicles best intrests.
We have begun fabrication of a much larger higher flowing unit that will be top mounted and fan forced. This will allow NO more thermal loads to be placed on the already "loaded up" engine cooling system and to do away with the damage the cooler cop's for being mounted so low.
I have no problems in posting the progress and pictures if you guys are intrested. I love build ups myself
Will keep you guys updated
Dont know if anyone is intrested, but we began development at work on an upgraded intercooling system for the 3.2 DID yesterday. The test mule is an NP GLS with 180 000km's on board.
As we all know the standard location of the factory cooler is less than ideal as it has minimal airflow and is prone to damage and clogging with mud etc. The core whilst being quite long has a very small stacked height, this combinded with the small tube sizes means that the cooler would be very restrictive. It is a common misconception that restrictive coolers must cool better, but it is far from the truth. As the amount of flow area( number of tubes x inside diameter of tubes) of the OEM core is quite small it means that the air has to speed up through the core. This means that as the air speeds up through the core it has less time to transfer its thermal energy into the coolers tubes. A larger higher flowing cooler allows the air speed to slow through the cooler thus allowing the air more time to be in contact with the internal surfaces of the coolers tubes and thus more time to transfer its load of thermal energy.
Ok, so while we had a fair idea that the OEM cooler wouldnt be that great, we were quite suprised on thermal load testing just how bad it can be! The ambient temp today during testing was 18deg C. A good intercooling system will be able to keep inlet temps to no more than 20 degC above ambient. My old 700hp Turbo Commodore maintained no more than 10degC above ambient on full noise. The 3.2 Paj showed us quite quickly that temps out of the turbo would exceed 150deg C on full noise, about the norm for most turbo deisels these days. The dissapointing thing is that after the cooler, temps were 116degC on the first run and then 126degC on the second run and still climbing. Please remember these are just quick power runs on the dyno taking no more than 15 seconds. I would love to hook a trailer on and test it full load up a hill but feel that would be not very nice to the vehicle at all. For obvious reasons these kind of inlet temps are not in the vehicles best intrests.
We have begun fabrication of a much larger higher flowing unit that will be top mounted and fan forced. This will allow NO more thermal loads to be placed on the already "loaded up" engine cooling system and to do away with the damage the cooler cop's for being mounted so low.
I have no problems in posting the progress and pictures if you guys are intrested. I love build ups myself
Will keep you guys updated
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