powerstroked08
Active member
Man this really has me scratching my head! I just cant understand why a better intercooler would hinder performance, especially boost.
webb06 official build thread
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it hasnt, to my knowledge affected anyone else, i know my silver truck gained 2+ psi of boost going to it from stock. it must have a blockage in it somewhere is all i can surmise. there's about 50 of those things out there with no issue that i am aware of. while i'm puzzled, i am happy he found the issue.
powerstroked08
Active member
Yes I agree that the only thing I can think of is a blockage in it somewhere. But it would surprise me since of the QC you had on these. But either way I'm glad its up and running right!
powerstroked08
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Is there a way to test for blocked tubes?
webb06
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I don't have a way to do it. Like a way to test flow of it
powerstroked08
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This may sound dumb but can you fill it most of the way up(almost to the top of the tubes)with cold water and then check the tube temperature with an infrared heat gun? Wouldn't the blocked tubes show up warm? Just thinking out loud.
madman1234509
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You also changed gate settings at well? Are you sure it was the intercooler causing the issue and not the gate opening?
Morgan@Midwest Diesel & Auto
New member
You could just cut the end tank off. I mean if it's bad it's bad. If you clean it out it could be tig welded back on. Should shed some light on what caused it.
powerstroked08
Active member
Very true.
webb06
Active member
Throughout all the testing today the boost supply for the gate was off. So there was no boost going to the gate to open it. Immediately after I swapped intercoolers boost was reading 52 on the factory sensor. On Dustin's harness I was seeing 56-57 so I have no doubt that boost is actually in the 56-57 area rather than 52.
Once I was done testing I hooked the wastegate back up and lost some boost. So I think the regulator is leaking air off. Haven't messed with that just yet
webb06
Active member
I don't really see what could be obstructing it? I can look all the way down both tanks and cant see anything there
no we have data to back up the intercooler issue
Before the change we were seeing 53 psi PRE intercooler and 46 psi in the manifold
Now its seeing 58psi PRE turbo and 56 in the manifold, def something wrong with the intercooler, what it is i dunno.
I think part of the gate issues now is that the engine is seeing MORE air than it was before so now back pressure too has come up, but at least the turbos arent working so hard to not get all that nice air flow into the manifold
This is all monitoring with two identical sensors in each pipe, same thing with the atmospheric pressure, good hard data no guessing going on. Trust me the last thing i wanted to do was condem the intercooler but the math wasnt making sense. It was crazy too that atmo was making 35psi at times with the no limit intercooler, the restriction did some odd things
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I am just trying to understand this, but where were you seeing the 58 PSI (? pre turbo)?
luckily he had a bung welded in the hot pipe already so we put a sensor in it.. when i say we Webb did all the work, i was just taking his data and trying to figure out WTF was going on. Most trucks dont have this option. Mine included
If you don't mind, I just want to clarify because some day I hope to add fuel and do a little different arrangement on the turbos so the bung setup will be handy in case there are issues. The 58 PSI was in the hot pipe connecting the HP turbo to the IC, right? Thanks.
correct, that was measuring right out of the high pressure turbo before it goes down and into the intercooler.
Post intercooler was measured in the manifold as it should be, i suppose if you wanted to get technical you could measure in the cold pipe and again in the intake, but if everything is ok there shouldnt be any loss.
From what i found asking around you should not have any more than 2psi drop across the intercooler and in the perfect world you loose 0 psi, but the gain in intake air temp drop is much better than the additional 2 psi of boost
Post intercooler was measured in the manifold as it should be, i suppose if you wanted to get technical you could measure in the cold pipe and again in the intake, but if everything is ok there shouldnt be any loss.
From what i found asking around you should not have any more than 2psi drop across the intercooler and in the perfect world you loose 0 psi, but the gain in intake air temp drop is much better than the additional 2 psi of boost
The only other thing i can think of that would cause the intercooler to get plugged would be a turbo failure putting oil in the intercooler, water/sludge combined (not sure what that would be from but i have seen in on machines) or something possibly wrong with the core or tank... too many things to go wrong
blk350on20s
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Did you have this issue as well Dustin?
Thank you. That is very helpful.
webb06
Active member
It's a no limit hot side pipe. That's why it's got the bung. The intercooler has no oil or anything at all inside of it.
