Ecoboost Intercooler Upgrade made in Germany
10-02-2012, 05:20 PM
#51
Has anyone tired to get a dialog started with the NHTSA and give them some of the info from this thread? I'd say if everyone with the condensation issue filed a complaint, it would definitely draw some attention.
I've been through this with our 2010 Jetta tdi. They had issues with DSG trans going in to neutral outta now where. So many people filed complaints with the NHTSA that certain VIN's were recalled. NHTSA will step in quick if there's a real safety issue. Ours was not a recalled vin but VW stepped up and gave 100k power train warranty to all 2010's to make sure the DSG didn't flop.
I personally haven't experienced the condensation issue probably because I drive my work truck during the week. My Eco never sees the right conditions for the condensation to happen. I live in KY and the air temp frequently bumps the dew point.
Everyone ban together to stir the pot and speak to someone at nhtsa.
I've been through this with our 2010 Jetta tdi. They had issues with DSG trans going in to neutral outta now where. So many people filed complaints with the NHTSA that certain VIN's were recalled. NHTSA will step in quick if there's a real safety issue. Ours was not a recalled vin but VW stepped up and gave 100k power train warranty to all 2010's to make sure the DSG didn't flop.
I personally haven't experienced the condensation issue probably because I drive my work truck during the week. My Eco never sees the right conditions for the condensation to happen. I live in KY and the air temp frequently bumps the dew point.
Everyone ban together to stir the pot and speak to someone at nhtsa.
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Maico Doug (10-02-2012)
10-02-2012, 07:21 PM
#52
GermanEB,
I like this Fluke Data Logger. Makes a comma delinated excel file. I used it for temp logging in a enviormental chamber. Works well with T/Cs http://www.bellnw.com/manufacturer/FlukeRef/2625A.htm
Yep, just this weekend 2 days of 5 each motor bogging episodes. Showed up at the dealer and asked "how many EB's do you have today after a very rainy weekend", the service manager answered "I'm having one IC removed & drained of water". The first service writer denied even knowing of any IC water condsation issue on the phone, so when I stopped by the service office, I went straight to the Service Manager. I told him to shoot straight w/ me, and that his writer denied any knowadge of the problem. He had the TSB up in less than a minute, and within another minute had the Senior Tech that was pulling the IC out for water meeting in his office. He agreed that Ford's fix of the upper air dam retrofit was not the best solution. I was out of there in 30 minutes w/ a new software flash and the new air dam parts on order.
Doug
I like this Fluke Data Logger. Makes a comma delinated excel file. I used it for temp logging in a enviormental chamber. Works well with T/Cs http://www.bellnw.com/manufacturer/FlukeRef/2625A.htm
Yep, just this weekend 2 days of 5 each motor bogging episodes. Showed up at the dealer and asked "how many EB's do you have today after a very rainy weekend", the service manager answered "I'm having one IC removed & drained of water". The first service writer denied even knowing of any IC water condsation issue on the phone, so when I stopped by the service office, I went straight to the Service Manager. I told him to shoot straight w/ me, and that his writer denied any knowadge of the problem. He had the TSB up in less than a minute, and within another minute had the Senior Tech that was pulling the IC out for water meeting in his office. He agreed that Ford's fix of the upper air dam retrofit was not the best solution. I was out of there in 30 minutes w/ a new software flash and the new air dam parts on order.
Doug
Last edited by Maico Doug; 10-02-2012 at 09:58 PM.
10-03-2012, 12:48 PM
#54
Found Intercooler on the Web
Did you work with Wagner Tuning on your intercooler design? I just saw an intercooler that looks exactly like yours that has their name all over it. Here is the link:
http://www.wagner-tuning.com/Ford-F-...oler_p_63.html
http://www.wagner-tuning.com/Ford-F-...oler_p_63.html
10-03-2012, 12:51 PM
#55
Originally Posted by texasbill
Did you work with Wagner Tuning on your intercooler design? I just saw an intercooler that looks exactly like yours that has their name all over it. Here is the link:
http://www.wagner-tuning.com/Ford-F-...oler_p_63.html
http://www.wagner-tuning.com/Ford-F-...oler_p_63.html
10-03-2012, 12:54 PM
#56
Oh ok...thanks...guess I should have put two and two together. One question I do have reguarding the design of the new intercooler is the position of the intlet and outlet tubes on the tanks. Is the position higher, lower or about the same as the OEM unit?
10-03-2012, 12:57 PM
#57
Originally Posted by texasbill
Oh ok...thanks...guess I should have put two and two together. One question I do have reguarding the design of the new intercooler is the position of the intlet and outlet tubes on the tanks. Is the position higher, lower or about the same as the OEM unit?
That shape of the endtanks is different...
10-03-2012, 03:43 PM
#59
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I think $1290 is a fair price for a unit that nice. I've paid in that neighborhood for larger intercoolers that weren't that well-built.
I don't see how this could possibly solve any supposed-condensation issues. If the theories are correct, it would actually get worse. That said, I knew before opening this thread that it would immediately be side-tracked by the condensation topic.
I, too, would like to see before/after dP and dT numbers before really considering purchasing.
Nice work, GermanEB!
I don't see how this could possibly solve any supposed-condensation issues. If the theories are correct, it would actually get worse. That said, I knew before opening this thread that it would immediately be side-tracked by the condensation topic.
I, too, would like to see before/after dP and dT numbers before really considering purchasing.
Nice work, GermanEB!
On the other hand the OEM design might be depending on that pressure gradient in hot climates to "drive" the temperature of the airflow significantly below the outside temperature.
Last edited by jaswood; 10-03-2012 at 04:11 PM.
10-03-2012, 04:02 PM
#60
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This Cooler does not have anything to do with a BMW Cooler... It just shows, what tools i am using to design an intercooler...
The Stock Intercooler is actually not very big for a 3.5l Twinturbo Charged Engine. The Position and and how it gets the fresh air, is a bit far from perfect...
As i am using this Truck here in Germany to pull a 10000lbs 5th Wheel Trailer, i figured out, that we are running into IAT Problems. Designing Intercoolers is Part of my Business, so it was not big deal to make somthing...
The Stock intercooler has actually very high density finns, it looks to me Ford was running into IAT Problems when they tested the Truck, also the fact, that they say, they strongly not recommend to use a Intake Gitter in front of the Intercooler is telling me the same.
About the condensate in the Stock Intercooler, its very hard for me to figure out why this is happening to a couple of people.
I am suggesting !!, that the density inside the cooler is to high, that results in to much pressure drop. The airflow is no high enough to transport the water fumes out of the cooler. Maybe it has a dead Flow Spot, where the water gets collected. But thats all a guess!! maybe someone with this Problem is willing to try my cooler.
The Stock Intercooler is actually not very big for a 3.5l Twinturbo Charged Engine. The Position and and how it gets the fresh air, is a bit far from perfect...
As i am using this Truck here in Germany to pull a 10000lbs 5th Wheel Trailer, i figured out, that we are running into IAT Problems. Designing Intercoolers is Part of my Business, so it was not big deal to make somthing...
The Stock intercooler has actually very high density finns, it looks to me Ford was running into IAT Problems when they tested the Truck, also the fact, that they say, they strongly not recommend to use a Intake Gitter in front of the Intercooler is telling me the same.
About the condensate in the Stock Intercooler, its very hard for me to figure out why this is happening to a couple of people.
I am suggesting !!, that the density inside the cooler is to high, that results in to much pressure drop. The airflow is no high enough to transport the water fumes out of the cooler. Maybe it has a dead Flow Spot, where the water gets collected. But thats all a guess!! maybe someone with this Problem is willing to try my cooler.
Now, where have I heard that before..??