So far, at least in my situation. This condensation builds up more easily at 55 to 60 MPH. If I am traveling above 75MPH, the engine all by itself seems better able to “eat the water” as it is made.

 

So i did some research on weather conditions when my truck fell on its face. It was back on march 22nd, and during a long steady state drive pulling an enclosed trailer. I looked at several weather observations along my route from March 22nd. During the 3 hr stretch with the cruise set at 72 mph, the dew point was within 5 degrees of air temp almost the whole time, and during part of the stretch, was nearly identical.

I only have the shudder when its colder out...but am beginning to wonder if its just because the dew point is closer to air temp at colder temps. Yesterday morning I could get the shudder to occur, dew point was around 20 degrees, temp was about 30. Later in the day shudder is gone, with air temp in the low 50's and dew point in the mid 20's.Not sure if it is correlated or not, have not had my truck for a Summer to see if the shudder will be there on really humid days, but will be keeping a close eye on it.

 

Thought this post I found kinda describes a lot of issues people are having, including running super rich and affecting mileage:



I've had my 1991 Eagle Talon TSI since 2001~2002 and I've had my MAFT setup for years. I run the MAFT and GM MAF as a basic replacement to my factory MAF, I actually tune with DSMLink.

Anyway this year I've noticed a new issue I've never seen before and I've narrowed it down to being a GM MAF issues.

Condensation builds up inside my intercooler, and when enough air starts passing threw my intercooler, it picks up water droplets and they are hitting the GM MAF, which throw the airflow singles all to hell and back, causing a SUPER instant rich condition which causes the car to fall flat, start bucking and in most cases, shut down.

I can't build ANY boost what so ever.

The only fix I've found is to pull off my damn bumper and then the intercooler and drain it.

Now here is what I don't get. I've had this car for years and I've NEVER had it do this.

If it rains one night though, I'm screwed. I can't even get to work the next day and it takes a week to dry out unless I drain it.

The system is air tight though so it's just from condensation it seems.

I can't imagine I've never had the condensation in my I/C before though. Why am I only seeing issues with it THIS year?

Could something be going bad? Could the GM MAF be dying? There is moister in the air and I'm sure other cars get water in there intercoolers too, I wouldn't think the GM MAF would be able to be shut down this easy.

I had to miss work yesterday again because I couldnt get to work. Any help would be GREAT.


Does anybody have the ability to read their boost levels that is having the shuttering issue to see if it appears that there is blockage caused by water in the intercooler? I'll probably be ordering the wireless OBD transmitter today so I can look at some of this on my phone.

 

And why did Ford change the MAF sensor some time after the beginning of the 2012 model year?

Later MAFs seem to have a dual function now. Not sure what?

 

I can't stop thinking about a neat gadget in the industrial world called a steam trap. What does it do? It automatically drains condensation that collects in pressurised steam lines. Seems to me at one factory I used to work in, we used small steam traps on the compressed air lines at the low spots in a run (like a drop to a machine) that you would periodically see blow off some condensate, then close up. All automatic. Who wants to start cobbling one of these on an intercooler?

 

How does it open? Wouldn't it cause issues if it opened during boost? Don't get me wrong, I'm all for a fix. Just curious how it would work in a system that would react to a change in pressure.

 

Hi All,

I found this in a patent that covers the same issues we are having. Makes for an interesting read.

Turbocharged and/or supercharged engine systems typi­cally include a compressor and an air cooler upstream of one or more combustion chambers of an engine. Often, the combustion air comprises a mixture of ambient air and recirculated exhaust gas in an attempt to reduce undesirable emissions produced during combustion. Recirculated exhaust gas often includes considerable amounts of water vapor and, in relatively cold environments, the temperature of the combustion air may be lowered below the dew point of the combustion air resulting in condensation developing within the air cooler. Under relatively high engine load conditions, e.g., at high torque, an air flow rate of the combustion air may be sufficient to purge the condensation from the air cooler. Under relatively low engine load con­ditions, e.g., at idle, the air flow rate of the combustion air may be insufficient to purge the condensation and, as such, an amount of liquid may accumulate within the air cooler. Accumulated liquid may be subsequently purged from the air cooler at increased engine load conditions, however, rapid engine increases may deliver a substantial amount of liquid toward the engine which may undesirably affect engine and/or air cooler durability and/or performance. Additionally, accumulated liquid may remain within the air cooler and may freeze causing mechanical damage to one or more components of the air cooler. Furthermore, the accu­mulated liquid within the air cooler may be aerated poten­tially causing physically sensed liquid levels to be inaccurate and/or difficult to determine.

 

Found what!!!!!!

 

I've added the statement to my post.

 

There are several different styles. I suggest heading to YouTube! It surely has a few vids. They only open when enough condensate is in them. It dosen't take much on a small trap.